Post-Maintenance Test Flights

At some point during aircraft ownership, owners are faced with the prospect of a post-maintenance flight test with a technician or shop representative riding shotgun. Depending on the level of maintenance the shop performed on the aircraft, a lot can go astray-and were not just talking about in-flight emergencies (although the odds of one are higher after heavy maintenance). And even relatively simple owner-performed maintenance chores, like oil changes or brake-pad replacement, have been known to create airborne drama. Whenever an aircraft comes out of maintenance, some sort of test flight should be conducted with the idea of verifying the work performed. In fact and perhaps unsurprisingly, the FAA has a regulation covering post-maintenance test flights, FAR 91.407. Its applicability to a specific situation hinges on the extent to which, if any, work on the aircraft "appreciably changed its flight characteristics or substantially affected its operation." Thats a fairly broad definition, and one an owner should think about whenever some maintenance is planned. But thats not all. Areas requiring consideration and planning for a post-maintenance test flight include piloting currency, insurance coverage, crew coordination and other FAA regulations, to name a few. For example, another regulation, FAR 91.305, states flight testing must be conducted over open water, or sparsely populated areas having light air traffic.

Key Takeaways:

• Post-maintenance flight tests are essential and often legally required (FAR 91.407) to verify work, as issues can arise even after minor maintenance or significant upgrades.
• Thorough planning is crucial, covering pilot currency, insurance, suitable weather (VMC), and adherence to regulations like flying over sparsely populated areas (FAR 91.305).
• The aircraft owner/pilot is always the Pilot in Command; they must be prepared, familiar with new systems, and prioritize safe aircraft operation over system testing or training.
• Effective coordination with the technician and ensuring all necessary aircraft documentation is onboard are vital for reducing risk during these serious and potentially hazardous test flights.

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