Budgeting for aircraft maintenance is a crucial consideration for aircraft owners and operators. For owners not enrolled with a maintenance program, what practices should they adhere to? Gerrard Cowan asks a panel of industry experts…
While a growing proportion of aircraft owners today opt to join an hourly maintenance program that covers their engines, Auxiliary Power Units (APUs), and a range of other critical systems and components, there is still a significant proportion of those who choose to fund maintenance demands directly, according to Michael Parrish, President and CEO of Elliott Aviation.
This is particularly true for owners operating older aircraft or flying lower annual hours, he elaborates – the appeal being largely financial and strategic.
The perception such owners have is that “it allows them to avoid fixed monthly payments, maintain tighter control over cash flow, and retain flexibility in how and where they maintain the aircraft,” Parrish says.
“In some cases, owners are also comfortable taking on the variability because they believe their overall costs will be lower over the life of ownership.”
This can be a risky approach but is a chance that a certain profile of aircraft owner is prepared to take.
The particular financial demands involved clearly depend on the system in question. Engines are almost always the largest cost driver, Parrish notes. Major inspections, hot section events and full overhauls represent significant capital outlays, and their timing plays a major role in total ownership costs.
Beyond the engines, key focus areas include landing gear overhauls, which are typically driven by calendar limits, “and can be expensive when they come due,” he says. APUs follow similar maintenance cycles, while avionics can be a major cost factor – particularly as systems age and upgrades are required for compliance or capability.
“In addition, time-limited components and certain structural inspections (especially on aging aircraft) can add meaningful complexity to the cost profile,” Parrish warns. The key point is that many of these expenses are not linear; they occur in larger, less frequent intervals, which makes planning essential.”
Therefore, estimating maintenance costs without a maintenance program requires a disciplined, data-driven approach, he says.
Elliott Aviation can work with owners to build a forward-looking maintenance forecast, based on the specific aircraft, its current condition, and its expected use. A review of maintenance records and logbooks is then aligned with OEM-recommended inspection intervals and component life limits.
“From there, we layer in our own fleet-level experience to model both scheduled and unscheduled maintenance events,” Parrish explains. “The end result is a realistic projection of cost per flight hour and a multi-year outlook that allows owners to plan with a much higher degree of confidence.”
This article was originally published by AvBuyer on September 15, 2026.