Are their any critical items that get overlooked during an annual inspection for a small single engine aircraft ?

lowlevel

Lots. Perhaps the most common is a borescope of the exhaust valves. Many of the “old school” mechanics think the cylinder leak down check is the primary indicator of engine health.. and as long as it’s 60/80 it’s ok. Or if they hear a leaking exhaust valve or it’s 59/80 they immediately pull the jug. What they are missing is to see whether the exhaust valve is showing signs of discolouration (as a result of combustion gasses blowing by it) or if it is simply sticking and can be repaired in situ by staking or the rope trick without the higher risk of a cylinder removal before it starts burning and fails in flight.

Anonymous

Not if it’s done correctly according to a tried and tested manufacturer-approved checklist. But humans make mistakes and human systems can be imperfect. So the answer will inevitably be “yes” and a significant number of air accident investigations have concluded such errors were a primary or contributing cause to such incidents.

0NE TRlCK P0NY

I only know of one. - a control line that was rubbing on a high pressure fuel pipe under the floor at the pilot's seat location for years. Came from the factory that way. - by the time it was found years later it had almost worn through the fuel line. In fact, when the mechanic bent the removed pipe it failed and opened up a 1/2 - 3/4" split in the the pipe. note - the mechanic received a more than generous ''tip'' from the aircraft owner.

Mercury

Not if you use a check list.

Denny

Every item on any inspection is critical from the aircraft records inspection to the final signature for the return to service. The question should be why is one item more critical than another? Any item can and will lead to an accident or incident regardless of how it is rated.