29 Dec 2025, 19:49 [ UTC - 5; DST ]
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Post subject: Re: Aerostars Posted: 30 Nov 2016, 21:34 |
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Joined: 09/25/08 Posts: 460 Post Likes: +518
Aircraft: 700P, F35, D17
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Username Protected wrote: Eric, will you share the story on your engine out?
Here is an odd story -
I flew from the midwest to Las Vegas 2 weeks ago, about 850nm, in my Columbia 400. The Columbia is a very comfortable, very capable aircraft (for VFR over the mountains) and is a 190kt - 225kt aircraft depending on your altitude and your LOP/ROP selection. Great cockpit, G-1000 which comes with the best autopilot around, really effortless with all the room in front of you w sidesticks. But - unless you go high, it's a 190kt ac which is actually a 165kt groundspeed ac when you're westbound at any altitude. Going high means the pulse oxymiter and the cannulas or mask. I did a variety of both low and high on O2, but was amazed at how fatigued I was that evening after just flying about 5.0 total. And the same thing on the way back - went faster, but on O2 the whole way, and done for the day on arrival.
I had a terrific 601p/700 that unfortunately had sat for about 10y prior to the time a guy found it, did some cleanup/upgrades, and sold it to me. Unfortunately I had 2 engine failures on S1A5MMs, had a hard time getting it worked on, and sold it because I could not depend on it. Always loved flying it - just had poor dispatch reliability.
After that Vegas trip - I cold-called the owner of my old Aerostar. From flight aware, it looked like it was getting used less. Sad story - the owner has lost his medical, and had just begun thinking about selling the aircraft. He's had it 10y or so and about 500h, bought it from the guy I sold it to - and has done impressive upgrades, fresh U2As on both sides, aux fuel, GTN 750/650, upgraded to Hartzell turbos and single waste gate controller on each side.
I am smitten - going to look at it next week - with a nod to serendipity.
Am I crazy to get rid of a 8yo latest technology efficient aircraft for a nearly 40yo ex girlfriend? I mean airplane?
The reason for the question for Eric - I need to get over the sting of those engines betraying me - twice - although each was a non-event and the aircraft flies easily on one. I keep reminding myself that's what I'm doing right now, flying with one engine out - Marty, I was leaving KCOT for KHOU (about a 175 mile flight). There was an MOA just outside of KCOT and ATC asked me to climb to FL230. I was climbing out at about 1500 fpm at about 150 knots indicated. As I passed through FL210 the right engine shut off -- no warning and no indication of anything amiss. I did not feather it immediately because I had so much altitude but the airplane began a descending right turn. With the prop windmilling there was no indication at all of the engine trying to restart. At 17500 I went ahead and feathered the prop and with a little left rudder hit the autopilot and the airplane continued along just fine on one engine. I asked ATC to allow me to stay at 17500 while I did some troubleshooting. The good news was that my flight path took me over airports that were all suitable landing sites and evenly spaced if I felt that landing was the best option. Because I was having no issues maintaining speed, altitude and heading I continued on and continued to analyze what I had. I was impressed that I could still climb if I needed to -- albeit I could only make about 400 fpm at that altitude on a single engine. It was at least comforting to know that I had a lot of reserve if necessary. As I descended through 12000 feet I unfeathered the prop and reintroduced fuel to the engine and it restarted normally and ran. Nevertheless, I reconsidered keeping the engine running because i did not know why it quit in the first place but I suspected a turbocharger issue. I decided since the airplane flew so well on one (and I did not know if I had lost an exhaust pipe or something else critical) I resecured the engine with the knowledge that it was probably there for me if critical. I landed at KHOU on one engine and taxied to my hangar. One nice byproduct of the Aerostar is that with the hydraulic steering you can still taxi on the ground normally with one engine. The only thing "odd" was that with the propeller feathered there was still a fair amount of drag from the dead engine. It was much more than "training" where you simply make the dead engine idle. The experience gave me a lot of confidence in the plane.
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Post subject: Re: Aerostars Posted: 30 Nov 2016, 21:44 |
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Joined: 09/25/08 Posts: 460 Post Likes: +518
Aircraft: 700P, F35, D17
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Username Protected wrote: Actually, since all of the work is being done in your own shop aren't you the last person to ask on how much one costs to maintain?  I have not found the A* to be a difficult, or overly expensive, airplane to maintain. Don't get me wrong, it is a complex go-fast airplane, it isn't like maintaining a Bo or a C182, but the systems are robust and well designed. But don't forget, you are maintaining an airplane that if manufactured today would cost well over a million dollars. In my opinion, one of the significant drivers of the escalating cost of ownership is the dwindling number of aircraft and the resulting escalation of per unit cost necessary to for service facilities to remain solvent. However, I must admit some of the charges simple are absurd. For example, Garmin charging a 1000 bucks to update software and change a $12 battery. I bought a battery off eBay and changed it on my desk in 15 minutes. If you are not willing, or able to do this expect to pay the above-quoted prices for the annual blessing of your aircraft. 
I am more in Jeff's camp. I have done an owner assisted annual every year and except for last year where I did two cylinders and a turbo my annuals have always been about $7000. With that said my airplane is kept in top shape all the time so I don't kick anything to the annual. When it breaks it is fixed. For that reason my annuals might be cheaper than the average.
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Post subject: Re: Aerostars Posted: 30 Nov 2016, 21:54 |
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Joined: 02/05/15 Posts: 381 Post Likes: +104 Location: KSLC
Aircraft: Divorced: AC690A-10
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Username Protected wrote: I am more in Jeff's camp. I have done an owner assisted annual every year and except for last year where I did two cylinders and a turbo my annuals have always been about $7000. With that said my airplane is kept in top shape all the time so I don't kick anything to the annual. When it breaks it is fixed. For that reason my annuals might be cheaper than the average.
Eric, do you mind sharing the cost of the turbo including labor? With four installed I'm guessing I should plan on one per year on average? Or four every 500 hours ?
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Post subject: Re: Aerostars Posted: 30 Nov 2016, 22:14 |
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Joined: 11/06/10 Posts: 12201 Post Likes: +3086 Company: Looking Location: Outside Boston, or some hotel somewhere
Aircraft: None
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Username Protected wrote: Eric, do you mind sharing the cost of the turbo including labor? With four installed I'm guessing I should plan on one per year on average? Or four every 500 hours ? I paid 1500 per for overhaul about four years ago. I put over 300 hours on the turbos after that, and the new owner said the turbos look great and are working fine. Tim
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Post subject: Re: Aerostars Posted: 30 Nov 2016, 22:46 |
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Joined: 01/14/12 Posts: 2001 Post Likes: +1494 Location: Hampton, VA
Aircraft: AEST
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Running LOP and using 1650TIT as the limit. A good O/H lasts 500hrs, after that issues may arise (like difficulty maintaining MAP at altitude at lower RPMs, or blowing oil). By 1000 hrs you'll have sent all four off. The other components that wear out about as fast as the turbos are the wastegates. The only place that does good work repairing (or replacing) wastegates is AAC, and they are expensive  items. (All this stuff is why you really want to go up to FL250 on the pre-buy test flight to verify everything is working as it should.) 
_________________ Forrest
'---x-O-x---'
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 06:43 |
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Joined: 02/05/15 Posts: 381 Post Likes: +104 Location: KSLC
Aircraft: Divorced: AC690A-10
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Username Protected wrote: They're abut $3.5-4K from AAC. Each ?
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 07:58 |
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Joined: 09/25/08 Posts: 460 Post Likes: +518
Aircraft: 700P, F35, D17
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Username Protected wrote: I am more in Jeff's camp. I have done an owner assisted annual every year and except for last year where I did two cylinders and a turbo my annuals have always been about $7000. With that said my airplane is kept in top shape all the time so I don't kick anything to the annual. When it breaks it is fixed. For that reason my annuals might be cheaper than the average.
Eric, do you mind sharing the cost of the turbo including labor? With four installed I'm guessing I should plan on one per year on average? Or four every 500 hours ?
No problem. The turbo factory remanufactured was $2900 netted with a $500 core. That is one right from Hartzell who now owns the rights. I replaced the wastegates with new ones from Aerostar and those were $3500 each. In terms of the labor to R&R the turbos I did it myself under the supervision of my A&P. It took me about 10 hours total to do the job. It is a very tight area to work in but with patience its just a dozen of hard to access screws and nuts.
Today my turbos are all working fine and, except for the new one, they all have about 700 hours on them. Another failure point for all of our airplanes is that the hoses are the same age as the turbos. I think how you operate the airplane and maintain it is directly proportional to how long the turbos last. Given that most turbo airplanes need cylinders mid life I would think the smart money would be to plan to do a top and the turbos at the same time.
The only reason I had to change the turbo to begin with was that it had a crack on the mounting boss that we found at the annual probably because the wastegate on that side was hung up. The turbo we replaced it with was a reman by Aircraft Accessories of Oklahoma. That one lasted 68 hours before it failed.
In terms of a little additional PIREP on the subject of turbos I sent it back to AAOK and they said it was FOD (I think that conclusion was complete BS) and they gave me no relief on the cost at all despite it only lasting 68 HOURS AND 10 MONTHS -- they even offered to rebuild it again for $200 more than what I paid in March 2016. Never heard of FOD at FL210 that could pass through a filter into a turbo. AAOK is off of my list and I would not send them a turbo ever again.
If you ever have AAOK reman a turbo keep your hand on the prop control in case you have to feather. That is why I put a factory reman on the plane this time.
Eric
Last edited on 01 Dec 2016, 08:14, edited 2 times in total.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 08:05 |
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Joined: 01/14/12 Posts: 2001 Post Likes: +1494 Location: Hampton, VA
Aircraft: AEST
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Username Protected wrote: They're abut $3.5-4K from AAC. Each ?
Yep.
And there are four.
The big reason to understand all this (and an Aerostar familiar shop will) is to understand that there is a lot more to evaluating (and maintaining) one of these planes than just TBO and annual inspections.
Folks buy 'em without budgeting for all the pricy do-dads that wear out and end up with a clapped out plane that never flies.
Sadly, too many of those planes end up purchased by owners who don't (or are unwilling to) understand what they are getting into. It never ends well for the aircraft (or the buyer).
There is another (option). ----- Apologies to AS/DV
A 600 Aerostar
Fast, economical, great handling and ride, extremely solid construction, excellent factory parts support, they just run and run.
The guys who own these planes, love them, back in the day of check haulers, there were lots of 600s running around.
There is no life limit on an Aerostar airframe.
(Always get a pre-buy by an Aerostar expert, they'll know what to look for)
This is a 600: https://youtu.be/o3Rd0gf3T88
_________________ Forrest
'---x-O-x---'
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 08:23 |
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Joined: 01/14/12 Posts: 2001 Post Likes: +1494 Location: Hampton, VA
Aircraft: AEST
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I've had good success with these guys. http://www.approvedturbo.com/Also, I'm at 1900+ hours (1500+ LOP) and still running the same cylinders. Good compressions, decent oil pressure, good oil analysis, clean oil filters, and one quart every five hours (AS 15-50). Plan to keep running them until something changes. 
_________________ Forrest
'---x-O-x---'
Last edited on 01 Dec 2016, 10:31, edited 1 time in total.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 08:25 |
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Joined: 09/25/08 Posts: 460 Post Likes: +518
Aircraft: 700P, F35, D17
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One other thing on the wastegates -- Aerostar will rebuild your existing wastegates if they ar repairable. In talking with them the issue will be whether or not they have enough material around the shaft area for them to drill out the hole slightly and install an oversized bushing.
I bought new wastegates this time because I wanted to get the plane back in the air. I also sent them the pair that I removed and they were both "rebuildable". They came back with all new guts and I put them on the shelf.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 08:28 |
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Joined: 09/25/08 Posts: 460 Post Likes: +518
Aircraft: 700P, F35, D17
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Username Protected wrote: I've had good success with these guys. http://www.approvedturbo.com/Also, I'm at 1900+ hours (1500+ LOP) and still running the same cylinders. Good compressions, decent oil pressure, good oil analysis, clean oil filters, and one at every five hours (AS 15-50). Plan to keep running them until something changes.  You da man.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 10:38 |
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Joined: 01/14/12 Posts: 2001 Post Likes: +1494 Location: Hampton, VA
Aircraft: AEST
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Username Protected wrote: I've had good success with these guys. http://www.approvedturbo.com/Also, I'm at 1900+ hours (1500+ LOP) and still running the same cylinders. Good compressions, decent oil pressure, good oil analysis, clean oil filters, and one at every five hours (AS 15-50). Plan to keep running them until something changes.  You da man.
At this point if any of those happy indications change Airpower gets a big check, but until that day it is kinda fun to run around without considering engine reserves in the cost of operation.
_________________ Forrest
'---x-O-x---'
Last edited on 01 Dec 2016, 14:54, edited 1 time in total.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 12:46 |
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Joined: 02/05/15 Posts: 381 Post Likes: +104 Location: KSLC
Aircraft: Divorced: AC690A-10
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Hmmmm. 4k for a wastegate x 4 . Instead of calling the airplane "well-supported," we should change it to "well-extorted." I talked myself off the ledge on the MU2. I think I'll go back there and look some more. It has pricey components, but they last and I don't think it has more than 2 of anything.
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Post subject: Re: Aerostars Posted: 01 Dec 2016, 15:23 |
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Joined: 01/14/12 Posts: 2001 Post Likes: +1494 Location: Hampton, VA
Aircraft: AEST
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Username Protected wrote: Hmmmm. 4k for a wastegate x 4 . Instead of calling the airplane "well-supported," we should change it to "well-extorted." I talked myself off the ledge on the MU2. I think I'll go back there and look some more. It has pricey components, but they last and I don't think it has more than 2 of anything. MU-2s are often the next step for Aerostar owners. I got some time in one back in the 90s, coming out of the 1900 (B & C), it rode nice, but it handled like a truck. Maybe Craig H. will come along and enlighten us on the wonders of the MU-2. Here's a nice article form back in 2008: http://mu-2aircraft.com/upload/news/MU2News_73.pdfIt has (2008) cost of ownership numbers..... $2,900.00/HR. 
_________________ Forrest
'---x-O-x---'
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