It took Air Mod (based at the Clermont County Airport [I69] in Batavia, Ohio) just a few days to tear out the Crossover Classic’s nasty old interior, pull up the floorboards, yank out the seats and side panels, and take a really good look at the aluminum and other structures that have been covered up for 33-odd years. This is a hold-your-breath time. So far, all interior inspections have shown the airplane free of corrosion–but none of them involved disassembling the airplane to this degree. Sure, the easily visible parts of the airframe may not have any corrosion, but what’s under the rug?
You can say that Air Mod, our chosen interior shop for several of AOPA’s annual sweepstakes airplanes, is fanatical about hunting down and treating corrosion. And for good reason. You can fix up an airplane to a fare-thee-well, but if the airframe harbors corrosion it may be the end of the line for the airplane’s economically useful life. It can cost thousands to rescue a badly corroded airframe; depending on the location of that corrosion–say, at the wing spar box or wing attach points–then you’re looking at a major restoration. Or a writeoff.
Luckily, our 1974 Cessna 182P showed no corrosion at first. But then Air Mod pulled up the seat rails and looked behind the sidewalls forward of the door posts. And voila! Corrosion. Luckily, this can be treated and restored. As for the seat rails, they need to be replaced anyway. The seat-latch holes are slightly elongated, which means the front seats may not stay latched in takeoffs or steep climbs. So in lieu of yet another 100-hour inspection, it’s out with the old rails, and in with a new set.
Corrosion is one thing. Plain old wear, tear, and rot is another. Air Mod’s procedure is to photograph and inventory all the worn items, and so we’ve included some of Air Mod’s photos in this post, as well as in the sweeps website’s “media” section. Of course, all of this precedes a zinc chromate treatment, followed by the design and installation of the new interior.
Other work is also scheduled to be performed at Air Mod–installation of the Monarch fuel caps, Knots2U wheel pants, and much more. Check back for more updates in the near future.