Repairing lightning strike damage on a glass cockpit in a piston plane is a meticulous and complex process that requires a thorough inspection, specialized knowledge, and often involves replacing multiple components. The extent of the damage can range from minor cosmetic issues to catastrophic failures of the entire avionics suite and flight controls. Due to the high-energy nature of a lightning strike, it is not a repair that can be taken lightly, as the integrity of the aircraft’s electrical and structural systems may be compromised.
The Initial Assessment and Structural Integrity
The first step in any lightning strike repair is a comprehensive and detailed inspection of the entire aircraft, not just the avionics. A lightning strike is a massive electrical discharge that can enter an aircraft at one point and exit at another, creating a path of damage in between. The entry and exit points are often the most obvious signs of a strike, appearing as burn marks, pitted metal, or small holes. Mechanics must also look for less obvious signs, such as:
- Pitting or welding on wingtips, tail surfaces, and propeller tips: These are common entry or exit points for a lightning strike.
- Rivets that have been popped or discolored: This can indicate internal structural damage or overheating.
- Burn marks on internal wiring or components: The path of the electrical current can leave a trail of heat damage.
- Control surface static wicks that are missing or melted: These are designed to dissipate static electricity, and a strike can easily destroy them.
The aircraft’s structural integrity must be verified. A lightning strike can melt or fuse internal components, and the intense energy can weaken or even crack the airframe. The inspection must follow the aircraft manufacturer’s and the FAA’s guidelines for lightning strike inspections to ensure the airworthiness of the plane. This step is a critical part of the repair process and must be handled with the utmost care and attention to detail.
Assessing Avionics and Glass Cockpit Damage
Once the structural integrity is confirmed, attention turns to the avionics. Glass cockpits, with their sensitive solid-state components, are particularly vulnerable to lightning-induced electrical surges. The intense electromagnetic pulse (EMP) from a strike can fry circuit boards, corrupt software, and cause displays to fail. The most common issues seen in glass cockpits after a lightning strike include:
- Complete failure of display units (PFD/MFD): The display may remain blank, show garbled data, or cycle on and off erratically.
- Failure of GPS/Nav/Com radios: The strike can destroy the internal circuitry of these units, rendering them useless.
- Damage to remote components: The strike’s energy can travel through the wiring to remote magnetometers, AHRS units, and other sensors, causing them to fail.
- Intermittent or inaccurate data: The displays may function but show incorrect airspeed, altitude, or attitude information due to sensor damage.
The principle of authority is key here—the repair must be performed by certified avionics technicians who specialize in glass cockpit systems. These professionals use specialized diagnostic tools to test each component individually and verify its functionality. It’s not enough to simply check if a unit turns on; a full system check is needed to ensure the accuracy and reliability of all data.
The Repair and Replacement Strategy
The decision to repair or replace a damaged component depends on the extent of the damage, the manufacturer’s policy, and the cost. Many avionics manufacturers, including Garmin and Dynon, have specific procedures for handling lightning strike damage. In many cases, components that have been exposed to a lightning strike cannot be repaired and must be replaced entirely to ensure safety and reliability. This is because a lightning strike can cause subtle, latent damage that may not be immediately apparent but could lead to a future failure.
The repair strategy should be methodical and comprehensive:
- Isolate and Replace Damaged Components: Each damaged component, from the display unit to the GPS antenna, must be replaced with a new or factory-repaired unit.
- Inspect and Replace Wiring Harnesses: All wiring harnesses that were in the path of the lightning strike must be thoroughly inspected for signs of damage, and in many cases, replaced. This is a critical step, as damaged wiring can lead to future shorts and fires.
- Re-installation and System Configuration: Once the new components and wiring are in place, the entire avionics system must be re-installed and configured according to the manufacturer’s instructions. This includes recalibrating sensors and performing a ground run and a test flight to ensure all systems are functioning correctly.
At The Aero Center, we understand the complexities of lightning strike damage and the importance of a thorough, professional repair. Our certified technicians have the experience and access to the necessary manufacturer support to properly assess and repair your aircraft. We understand that your time is valuable, and our 24/7 operation in California, Arizona, and Nevada ensures that we can begin the repair process immediately, minimizing your aircraft’s downtime. Our goal is to get you back in the air with confidence, knowing that your aircraft and its avionics are safe and fully functional.
Footnotes
- AviationPros, “Lightning Strikes: When the Sky is No Place to Be,” AviationPros, 2017. https://www.aviationpros.com/aircraft-maintenance-technology/aircraft-technology/article/12285141/lightning-strikes-when-the-sky-is-no-place-to-be
- Aircraft Owners and Pilots Association (AOPA), “When Lightning Strikes,” AOPA Flight Training, 2013. https://www.aopa.org/news-and-media/all-news/2013/november/27/when-lightning-strikes
- Federal Aviation Administration, “Pilot’s Handbook of Aeronautical Knowledge, FAA-H-8083-25B,” FAA, 2016. https://www.faa.gov/regulations_policies/handbooks_manuals/aviation/phak/media/pilot_handbook_of_aeronautical_knowledge.pdf
- Garmin, “Garmin Aviation Products Manuals and STCs,” Garmin, 2024.
The Aero Center is located at William J. Fox Airfield KWJF | Lancaster, CA. Contact us at 209.885.6950 for questions or appointments.