Gather all maintenance logbooks and records for the Piper aircraft being rebuilt. Research and track down as many of the records as possible. Go over the documents and look for any "ADs," also referred to as airworthiness directives. These are issued by FAA inspectors and are tagged to the aircraft for the life of the plane. All ADs must be adhered to for the plane to be flight legal.
Assemble all necessary parts and equipment needed for the rebuild based on the records, shape of the aircraft and ADs issued. If the plane has not undergone an FAA annual for the current year, or has lapsed in registration, contact the FAA and schedule an inspection to ensure any new ADs issued are adhered to.
Bring the Piper aircraft to the hanger to begin the rebuild work.
Strip the fabric off the airframe. Remove the propeller and disconnect all steering and gauge cables. Attach the engine to the crane and remove it from the aircraft frame.
Inspect all airframe bars and beams. Check the rivets and welds. Restore welds and any damaged airframe bars. Stretch new fabric or carbon fiber sheets over the airframe as necessary and according to the new Cub guidelines issued at Piper.
Overhaul the engine according to the make and model. For example, a Lycoming 180 requires different overhaul methods than a Continental TSIO-360-RB 220hp. Use the aircraft operations handbook and mechanics manual to overhaul the proprietary engine.
Inspect the rudders, empennage (tail controls), wings and flaps and make sure all connections are in full FAA accordance.
Install the overhauled engine and reconnect all pitot-static gauges. Attach all steering controls from the stick to the rudders, ailerons, tail and trim. Place a new propeller on the aircraft. Install new tires on the two front and single rear landing gear assemblies. Schedule another FAA inspection to get approval for airworthiness and legality for the rebuilt and restored Piper aircraft.
