the true cost of engine overhaul

[j3gq]

I am sure this subject has come up before, but I can't find the details needed.

Many publications discuss the cost of an engine overhaul, different options, different suppliers, etc. Yet I would like to know how much more the aircraft owner has to put aside for the items typically not included. And numbers from within the last 5 or max 10 years are of course more interesting than older bills.

Consider your IO-360 has lasted 30 years and never failed, and now it's time for major work. Engine accessories are almost always included or listed, but what about the following firewall forward items which aren't any younger : engine mount - inspection and repair, exhaust - new (if welding isn't economical), oil cooler, and the related cost of labor, shipping, taxes, etc. Anything one cannot simply postpone until it really requires replacement or overhaul because that would come even more expensive.

Any real data / bills / experience on this very welcome. It is clear that the cost will vary a lot from case to case. Would could be a worst case ?

[jetdriven]

Don’t foget the prop.  The prop governor. The hoses. Scat hoses. Baffles. Baffle seals. Wiring.  Engine isolator mounts. Adel clamps and labor. 

I did the work myself under supervision and paid the shop 2k. Resealed the prop for 200$. Exchanged the governor for 1200$.  Hoses 950$. Reused exhaust. Repainted the engine mount. All in it was around 6-7k over the cost of the engine on the pallet. A fresh rebuilt factory lycoming io360a3b6 is like 29k now plus freight so it’s a 37-40k job laid-in right now if you go that way. 

[Jerry 5TJ]

21 hours ago, j3gq said:

Any real data / bills / experience on this very welcome. It is clear that the cost will vary a lot from case to case. Would could be a worst case ?

Quantitative Reply — Overhaul cost figures will vary over a huge range. As a middle-range baseline: Start with factory overhaul assuming good core credit, and a prop overhaul.  Add accessories and labor.      

Worst case — Your engine turns out to have no core value, your prop blades and hub are junk, and all the many Firewall Forward (FF) items need replacement.  Go price a new engine at outright cost, a new propeller, add the accessories and 120 hours of labor.  That’s about as bad as it gets FF.  

Qualitative Response — Everything takes longer and costs more (Than you expect).

But — a new engine in a good Mooney airframe is a joy to fly.  

[Hank]

Don't forget new throttle, prop and mixture cables . . . . .

[flyboy0681]

5 hours ago, jetdriven said:

Don’t foget the prop.  The prop governor. The hoses. Scat hoses. Baffles. Baffle seals. Wiring.  Engine isolator mounts. Adel clamps and labor. 

I did the work myself under supervision and paid the shop 2k. Resealed the prop for 200$. Exchanged the governor for 1200$.  Hoses 950$. Reused exhaust. Repainted the engine mount. All in it was around 6-7k over the cost of the engine on the pallet. A fresh rebuilt factory lycoming io360a3b6 is like 29k now plus freight so it’s a 37-40k job laid-in right now if you go that way. 

Our exact experience in terms of the "extras". Exact.