Pre-Flight Corrosion Walk-Around: A Printable Aircraft Checklist

Pre-Flight Corrosion Walk-Around: A Printable Aircraft Checklist

Already know what corrosion looks like and why Tucson's climate makes it a year-round concern? Skip the theory — this is the field checklist. Print it, keep it in the hangar, and run through it before or after any flight, especially during monsoon season.

New to corrosion inspection, or want the full picture on how it forms and progresses first? Start with our complete guide: Aircraft Corrosion: The Unseen Danger in AZ Skies.

In this checklist you'll cover:

  • Exterior surfaces, fasteners, and lap joints
  • Landing gear and wheel wells
  • Engine compartment and cowling
  • Interior and hard-to-reach areas
  • Drainage and vents
A red checkmark fills the top box of three vertical, empty, black-outlined squares on a white background.

1. Exterior Surface Inspection

[ ] Paint Condition: Check for bubbling, cracking, or "pimples" in the paint. This often indicates corrosion tunneling underneath (filiform).

[ ] Fasteners & Rivets: Look for "smoking rivets" (black streaks) or white/grey powder around rivet heads.

[ ] Lap Joints: Inspect where skin panels overlap. Look for "pillowing" or bulging between rivets.

[ ] Piano Hinges: Check aileron, elevator, and trim tab hinges for stiff movement or white powdery deposits.

[ ] Leading Edges: Inspect for pitting caused by desert sand abrasion that has stripped protective coatings.

2. Landing Gear & Wheel Wells

[ ] Wheel Wells: Check for accumulated mud, salt (if flown from coastal areas), or debris.

[ ] Brake Lines & Fittings: Look for galvanic corrosion where steel fittings meet aluminum components.

[ ] Struts: Inspect exposed oleo struts for pitting or scoring that could damage seals.

3. Engine Compartment & Cowling

[ ] Battery Box: Check for acid leaks or white "fuzz" on terminals and the surrounding structure.

[ ] Engine Mounts: Inspect steel tube mounts for rust, especially at weld points.

[ ] Exhaust Stacks: Look for thinning metal or scaling.

[ ] Cylinder Fins: Check for localized discoloration or salt-like deposits.

4. Interior & Hard-to-Reach Areas

[ ] Bilge/Belly: Open floorboards to check for pooled moisture or spilled fluids.

[ ] Wing Roots: Inspect the area where the wing attaches to the fuselage.

[ ] Tail Cone: Use a flashlight to check for condensation trails and oxidation on the internal bulkheads.

[ ] Control Cables: Feel for "snags" or rough spots that indicate internal cable fraying or rust.

5. Drainage & Vents

[ ] Drain Holes: Ensure all belly and wing drain holes are clear of wax, dirt, or insect nests.

[ ] Fuel Sumps: Check for water in fuel samples, which can lead to microbial growth and tank corrosion.

We hope you find this list helpful. On this page you should have found:  A systematic inspection is the only way to catch "silent" corrosion before it becomes a safety hazard. By following this checklist seasonally—especially after the monsoon season in Tucson—you protect both your aircraft's value and your passengers' safety. If you find anything suspicious, have it evaluated by an A&P mechanic immediately.

Contact Premier Aviation Tucson for any of your aviation repair needs.