When it comes to airplane makeovers, sometimes we have the urge to do all the work ourselves, and sometimes we just want someone else to do it for us. If we choose to take the plunge ourselves and tear things apart piece-by-piece, we occasionally get so deep and so overzealous that we eventually find that we are in over our heads. However, there are times when we’re simply very thorough, as is the case with the makeover of Guy Gismondi’s PA-23.

In July of 2003, Guy and his wife were flying over Lake Michigan on their way home from EAA AirVenture, when she mentioned they needed a larger aircraft with twin engines. Because Guy flies IFR during the early mornings and late at night, much of which is over water, the Gismondis decided to purchase an Aztec. They bought the plane in June 2004 and reassembly was complete in February 2005. The 1977 Aztec F was a step up from their 1969 M20 E Mooney, another airplane Guy had done a makeover on.

Guy set the timeline for the Aztec makeover at four-to-five months and wasn’t surprised when the work was completed three months past the projected deadline. Guy was thorough with this makeover. With the help of an A&P, he took everything apart, inspected every crevasse and replaced virtually everything that needed attention. In Guy’s words, “The project took on a life of its own. I fixed one thing and another item cropped up. I had to ask myself, do I stop here or fix it now, rather than later?”

Modification to the twin engines included new mounts, bushings, clamps, hoses, exhaust systems, and new belts for the alternator. He also had to rebuild both air boxes, install new supports for the oil coolers and rebuild the mags. In addition to the engine mods, Guy also had the air line to the horizontal stabilizer boots replaced because it was cracked, and the servo units were rebuilt.

The Aztec’s interior and insulation were completely removed and replaced. New zinc chromate was applied where necessary and the insulation was replaced with double-layered super sound-proofing. Finishing touches included all new leather interior, carpeting and plastics. After they inherited their son’s German Shepherd (Dakota) when he left to fight in Afghanistan, the Gismondis added plastic seat covers for the dog, who loves to fly with them. Guy also washed the entire tail down with mineral spirits.

Other modifications included all new stainless steel screws, new boot lines to the tail section and new rubber trim. Because much of the avionics and instruments were already working well prior to the makeover, Guy decided to put his energies into the engines and interior. “Much of my budget went to the overall performance of the airplane and rebuilding it from the ground up,” he said. “The overrun on the budget would have been spent on a Garmin GNS 430, (a WAAS-upgradeable IFR GPS, Com, VOR, LOC, and glide-slope with color moving map in one multipurpose unit), but my handheld will have to do for the time being.”

When asked what advice he would give to other owners considering a makeover, Guy responded, “Take your time and prioritize the project. Have a list of important tasks which must be done and a wish list of to-do items.” Most importantly, he advises that owners stick to the list, because others will have their own agendas. “It’s your airplane and you will be the one flying it,” he added. “Make sure you are doing the right things and making it better and safer.”

When asked if he would do anything differently, Guy affectionately referred to his airplane as “the other woman” (his wife’s nickname for his Aztec during the makeover), and went on to say that he would control the timetable and schedule. After tearing it apart and evaluating what needed to be done, he would have stuck to that priority list.

In the end, Guy really wanted other owners to know “that the airplane needed a lot more work than the pre-buy revealed.” His advice when you are shopping for a new/used airplane is to have a more complete pre-buy. “These are the little things that make the difference,” he said. “If you fly at night or over water, you certainly want everything to be just right. It may be an older airplane, but it doesn’t need to fly like one.”