On December 17, 2022, we took delivery after about a full year of maintenance. 620D went through a transformation from an old airplane to a restored classic ready for more. She is now IFR ready being /G (slant golf).
Still remaining on the wish list are tip tanks and exterior paint. But, after a year of maintenance we are ready to fly, fly, fly again and put all this effort and cost into some cross country enjoyment.
A huge thanks to Jeff for putting in the time and effort to rebuild the interior from the leather Airtex kit we ordered. They didn’t have instructions for our specific make & model, but Jeff was able to piece it all together and it now looks and feels spectacular. From tired old seats that dated the plane with their orange and yellow stripes to modern new cushions that support our weight and look and smell amazing. Jeff spent countless hours in his garage tearing down the seats and panels down to the bare metal and them building them back up to a completed product. Thank you Jeff!
During this process, we made so many changes. Some of the major changes to the engine were:
Top Overhaul – three cylinders were removed. One was replaced and two were refurbished. Have a look at this photo showing the crack which led to the replacement.
Primer Lines replaced – worn and crack lines and connectors were completely redone.
Battery Box – A new battery box was added and placed forward of the firewall improving CG a tad and placing it where it is way more accessible. Also, a quick connect was installed for trickle charging when the plane is parked.
Exhaust Repairs – In an attempt to clean up some exhaust leaks, the pipers were removed and sent in for repairs. The surfaces were sanding and cleaned up.
Generator to Alternator – The generator was removed and replaced with an alternator and now we have access to all the power we need on the ground at low RPMs.
Rear Headphone Jacks – Since we didn’t have any rear jacks, headphone jacks were placed inside the rear ashtrays. We also had USB ports installed in the backseats for easier access to power for passengers.
Wheels and Brakes – The wheels and brakes were completely replaced. Now, Cleveland brakes are installed, providing a much needed upgrade to the original brakes which were always sub par. The brake lines were shortened as well per the recommendation from Bob Ripley during the ABS Service Clinic.
Shoulder Straps for the Seatbelts – The new shoulder straps are completely installed and retract similar to how they retract in a car. They are very comfortable and easy to use. In my opinion, more comfortable than the center, over the shoulders harnesses.
Rechromed the Retractable Step – I am so excited about this upgrade! The chrome step was sandblasted and rechromed. Then, a new skid sticker was applied with a red Bonanza “B”. It looks absolutely amazing and really gives a great impression.
Landing Gear Hardware – New landing gear hardware was installed along with some new boots.
Flaps – Bob Ripley discovered that the flap rollers were installed backwards. Apparently, that’s a common occurrence. Those were fixed and the flap cables were lubricated.
Landing Gear Motor – The entire gear motor was removed and refurbished. The box had a slight leak but fortunately, it wasn’t bone dry inside. All parts were cleaned and inspected. The box was painted and resealed. Although it sits under the front seat and you’ll never see it, it is great to know it’s in like new condition.
Ruddervators – Removed, stripped, sealed and repainted. We were definitely worried about possible corrosion, so this will provide us with years of service, especially now that 620D is in a hangar.
Insulation – Noise cancelling insulation was installed throughout the interior walls of the cabin.
Cleaning – Literally, pounds of grease, dirt and grime were removed. Almost every surface was scrubbed from the floor boards, engine compartment, wheel wells and so many other areas. We probably added 10 pounds to our useful load!
All this and more was done over the past year. Not to mention the new panel and all the great avionics we can now enjoy. But that we’ll cover in another post.