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 often required by FAA regulations (FAR 91.407) to verify work, especially after significant changes or upgrades, as even minor maintenance can lead to in-flight issues.
• Thorough planning is crucial for these tests, encompassing pilot currency, insurance coverage, crew coordination, understanding new systems, and conducting flights in good weather over sparsely populated areas per FAR 91.305.
• The aircraft owner is always the Pilot in Command and must be prepared, current, and familiar with the aircraft and new equipment; the flight test is not a training session for the pilot or technician.
• Maintain open communication with technicians, as their comfort and willingness to fly are indicators of both aircraft airworthiness and pilot proficiency, and their refusal should prompt serious investigation.

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