Filling your aircraft’s oil might seem straightforward—until it isn’t. I’ve heard some wild oil-filling stories—and one sticks with me. A Part-145 DOM friend recently called and asked me to send some FunnelCaps ASAP after a VIP flight. Their Lear 45 pilots needed to top up oil before the next flight, and—believe it or not—they used champagne glasses from the galley to fill the oil.
The result? Oil spilt everywhere, precious time wasted cleaning up. An unnecessary disruption of the preflight preparations, and of course, a real risk of contaminating the engine. As funny as it sounds, it highlights a serious issue: pilots often aren’t fully aware of the risks of Foreign Object Debris (FOD) when filling oil.
Why This Happens: This is far from unusual. Pilots are often asked to top up oil without the same training that maintenance personnel receive. They’re not taught about Foreign Object Debris (FOD)—the tiny particles that can sneak into an engine oil system and cause serious damage. Yet, every day, pilots handle oil cans and openers, often unaware of the invisible threats they might be introducing.
And pilots, without FOD training, are particularly vulnerable. Working with cramped filler openings, awkward angles, and improvised tools—like a champagne glass—means oil spills and contamination are almost guaranteed. I’ve heard too many stories of pilots struggling to fill oil because they did not have the proper tools and knowledge.
I’ve spent over 33 years in aviation maintenance, holding EASA PART-66 and FAA A&P-I licences. I’ve worked on everything from sports planes to small airliners, audited maintenance lines, and managed both line and base operations. In all that time, I’ve learned one thing: even the smallest particle can cause enormous damage. Bearings, gears, and oil nozzles are delicate. A tiny metal shaving, a speck of dirt, or even leftover debris from a poorly opened oil can can lead to accelerated wear, overheating, or worst-case scenario: catastrophic engine failure.
“Awareness Is Your First Line of Defense”
The key here is awareness and care. Every time you fill oil, approach it as a critical step, not a mundane chore. Minimize spills, control debris, and avoid introducing anything foreign near the engine. Pilots often fill oil in tight spaces and challenging conditions, so having proper FOD-free tools like FunnelCaps readily available is crucial. It may feel like a minor step—but in aviation, the smallest particles can have the biggest impact on engine reliability and safety.
My Final Thoughts: I’ve seen the consequences of neglecting these details. And I don’t want pilots—my friends, my colleagues, anyone flying small aircraft—to face engine problems that could have been prevented. Safety isn’t just about following checklists. It’s about understanding the risks, respecting the machinery, and maintaining focus on the smallest details.
So the next time you fill your aircraft’s oil, remember: it’s not just pouring oil. It’s protecting your engine, your plane, and ultimately yourself. Treat it with care—and be mindful of the invisible threats that could compromise safety.
