We're starting with a 1973 "M" model Skyhawk.  An all original aircraft for this refurb. Only 1890 total time since new and original Cessna paint and interior. Enjoy !

Most all the exterior paint is now removed including the paint on the flight controls. The interior is also being removed to reveal a very clean internal airframe.

Nearing the final stages of cleaning, we got the cowl done and are ready to clean everything on the nose in preparation for the new engine. We got the doors removed and are cleaning all the jambs and facings. I just put the firewall through the first of several cleanings it'll get before its finished. Looked good before, but looks great now. Got the propeller all cleaned and ready for primer and paint !


                   

Now we've pretty much turned the corner on this job. That means that the majority of the work now will be focused on refinishing and putting things back on. There's still the engine to remove and few other items to take care of, but for the most part everything now will be on its way back.

The doors are removed and cleaned of all paint, door seals, and door seal glue. They are now ready for prime and paint. They'll get the same process as the exterior.

All the door jambs were painted with Gamma Grey including the baggage compartment. Lots of taping and masking to get this done.

Painted the baggage compartment door jamb to match. A small detailing spray gun works good for this.

           

After careful sanding of the epoxy corrosion primer, the final finish is applied. Three coats of Jet-Glo Matterhorn White.

               

Back in our paint booth the flight controls, spinner, and other miscellaneous parts are primed and painted. The flight controls are installed next using new stainless steel structural screws in the ailerons and new bolts and nuts for the tail surfaces. All bushings and bearings in the tail are cleaned, greased, and any worn items replaced with new.
   

The engine cowl is primed and painted on both sides. I like to use Jet-Glo Gamma Grey for the inside of the cowl to help prevent corrosion and provide a clean environment to help detect future problems with oil leaks, etc.

For this project, we'll be using a Lycoming Factory Overhauled engine. The new engine has to be prepped for install by changing out any fittings and brackets that are needed for installation.

Here we see the old engine removed and the new engine set in place. The firewall, battery box, gascolator, and every other little thing I can find is cleaned and refinished.

The engine baffles are all cleaned, repaired, primed,  and powder coated. Also powder coated other brackets and generally cleaned everything up under the cowl.

Back on the interior, we install new high density sound dampening material, all new carpeting, and refinished interior plastics. The interior wall panels are upholstered in leather with a cloth trim.

                   
Believe it or not these are seats. The first photo is what's left after the cushions, cushion supports, and upholstery is removed. We cleaned these down and repainted with Jet-Glo Gamma Grey and installed all new cushion supports before upholstering with leather.


Also installed a four place intercom system while we were at it.

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Now we begin to see it all take shape. Installed the wheel fairings, wing tips, and other small parts. Also did the stripe layout using Jet-Glo Regatta Red, Medium Scarlet, and Gamma Grey. The last shot is of my friend Chris just before he took it out for the first ride.

And now, some before/after pix :

    Before                        After                    Before                    After                    Before                  After

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