Bushliner | Aircraft Remanufacturing

Bushliner: Building a better Cessna

  • The Cessna 180 and Cessna 185 are highly capable aircraft that are no longer in production. No current aircraft on the market offers the same performance or has the same reputation as the Cessna Skywagon family.
  • These aircraft were originally manufactured prior to modern techniques being developed. Unfortunately the existing Cessna 180 and 185 fleet is deteriorating beyond economical repair.
  • Cessna anticipated the aircraft would be needed for, and designed them to last for 15-20 years of normal use. Many of these aircraft are well beyond 40 years old and have been abused hard for that time. 
  • Integrating upgrades into the aircraft during the overhaul is key. Every component is epoxy primed, structural reinforcements added, and all critical fasteners are replaced with modern hardware over three times stronger. Integrating the latest manufacturing practices.
  • By making these improvements, the aircraft will last for over a century, even when operated in the harshest environments.
  • Our aircraft are designated “equivalent to new”, which gives the purchaser equity, and confidence in the reliability of our aircraft.
  • They are familiar to pilots and mechanics worldwide, furthering the legacy and popularity of these models.

Our Process

Disassembly

Each aircraft undergoes a complete tear down. Every rivet or other fastener is removed, including each sub assembly. Components are harvested and individually inspected to determine quality.

Component refurbishment

  • Steel welded components NDT inspected, epoxy primed, enamel topcoat.
  • All structural aluminum machined parts anodized per AMS 2700
  • All aluminum structural components disassembled, inspected per Cessna Maintenance Manual 51-11-00, cleaned, etched, chemically treated (alodine) per MIL-C-81706 and epoxy primed prior to assembly per AC43-4B. Or rejected and replaced.

Assembly

  • All fatigue components replaced or upgraded to latest configuration. (Gearboxes, spars, horizontal stab attachments)
  • Complete assembly in a Cessna Factory Jig. (Cessna built the aircraft in two parts, attached later, which caused dimensional errors of over 1″ in some cases.)
  • Fuselage reinforcements added.
  • Systems (such as electrical) upgraded to comply with new safety regulations.
  • All refurbished components QC stamped and logged.
  • All bearings removed, bores inspected, cleaned, and new bearings installed.
  • All eligible fasteners superseded.
  • All AD’s and SB’s complied with or eliminated, and a new MX schedule included