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PSA: I just hit 500 hours on a single engine overhaul and the number shocked me
I'm a GA guy, mostly working on Cessnas and Pipers. I just finished a full overhaul on a Lycoming O-360 for a local flight school. When I tallied my log, I was at 502 hours from teardown to final sign-off. That's double what I estimated to the owner back in January. The big time sink was chasing down a persistent oil leak from the crankcase halves, which took three separate reseals over two weeks to fix. I know shops quote based on book time, but real world hours can blow right past that. How do you all handle giving estimates on major work when hidden problems pop up?
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