Durn it. Seems this thread is done. I sorta feel like my favorite soap has ended and now there's a hole in my day
Blimpster, here's where you want to start: AC 23-27 Parts and Materials Substitution for Vintage Aircraft
http://rgl.faa.gov/REGULATORY_AND_G...ac581048cd862575e6006ca078/$FILE/AC 23-27.pdf
Read it, every single word. Then read it again. Become an expert in this document. Like Lancelot's Sword, this AC is powerful if it's used wisely. It was written specifically for the purpose you've been working on. You don't have to be an A&P to use it.
Once you've assimilated that AC, now go do the same for AC 23-21 Airworthiness Compliance Checklists Used to Substantiate Major Alterations for Small Airplanes
http://rgl.faa.gov/Regulatory_and_G...8c09686256fe8005c605c/$FILE/AC 23-21CHG 1.pdf
This one is your roadmap to success. Don't skip a single word.. understand it all.
Only after you totally grog those two ACs do you want talk to the FAA. Why? because if you don't know what you're talking about, they'll realize it right away and you're toast. BUT, go in with that knowledge, be nice, positive, and show some empathy for their situation and you might find out they'll actually help you.. a lot.
<SOAPBOX MODE ON> (to any and everyone that whines about the old days)
I'm old enough and have owned planes long enough to remember when the annual was required to renew your airworthiness cert. I remember the "old days" too. they're gone, things changed - let it go. You want to fly your old plane now, now is where you have to function.
The FSDO inspectors are there to make sure no one violates the regs. That's it. Put yourself in that position.. If you always say no, the regs wont be violated and you'll keep your job (and limit your exposure to litigation). Walk in there whining about the old days and they'll ask you to find success elsewhere. Tell them you cant understand why it takes so much effort for something so simple, they'll just tell you to go away and come back when you understand...
The really don't care what you want to do, as long as you do it according to the rules.
Nowadays, thanks to politics and all that goes with it, there's far to few of them trying to hold the fort. (keep that in mind when you go to the polls in 2015) Then some Korean knuckleheads claims he got blinded by light and lands on a breakwater in KSFO..
<SOAPBOX MODE OFF>
OK, so now you're an expert. Hide that. Showing off is arrogant. Call the FSDO, ask for an appt. Tell them you have an "Aging Aircraft" (don't say old plane - to them a 80's Skylane is old). Tell them you read the ACs and would like to follow them to get a field approval for Brake Master substitution, and you'd like to open a line of communication for advice so you can do it right the first time. Be patient and positive even if they're not.
Don't be surprised if all they say os to follow the ACs and submit some paperwork - only to have them kick it back requiring some more work. Thank them for their attention to detail and do the work, keep being nice and patient. Eventually you get through it not only with your approval but also with a huge boost up the learning curve and, if you've kept a positive and constructive attitude, new friends at the FSDO. Next one will be much easier.
It seems every time I'm in my FSDOs (San Diego and Riverside) the only time there isn't someone whining about some reg is when I'm the only one there. They didn't write them, they just have to enforce them. Show them you want to help, they'll love you.
Of course if all this is too much for you, you can always retain a DAR (I make nice Bellanca-Bux that way, that's how I paid for my IFR stack) or, Barnstormers has Cessnas listed every day....
Don't feel alone. 30+ years ago I went through the field approval education when I bought a metalized Stinson for a song... then found out why. It's what resolved me to go to A&P school, then become an IA - well that and because it was fun. One day the Inspector mentioned they needed more Designees for aging aircraft issues and asked if I was interested... Now, I walk the dark side, but I carry a big flashlight :twisted: