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November 2013


Beech 200 - P & W PT6 - Cardiff - 14/08/2013 (201310598)

Flight crew injury from main cabin door hydraulic dampener failure.  Crew member opened the main cabin door from outside the aircraft and it fell freely impacting and causing injury to the crew member's left shoulder. Hydraulic fluid was evident on the internal top step indicating a leak from the dampener assembly. Tech Log entry made and crew member attended hospital. 

Beech 200 - P & W PT6 - Cranfield - 05/11/2013 (201314234)

Incorrect parts installed found during routine maintenance. The thrust bearings installed in the main landing gear actuators were discovered to be not as per the CMM.  Bearings had been installed at the last component overhaul in March 2010. Overhaul agency informed.  

Beech 33 - Continental 470 - Hythe - 25/10/2013 (201314510)

Exhaust stack on LH side found severely distorted, holed and improperly repaired.  A homemade circular band was clamped round the body of the exhaust in an attempt to cover a large hole in the stack. The RH side stack was also cracked. Adjacent engine components and cowling access showed signs of heat distress. Considerable combustion deposits found within engine compartment.  Both regulator garter filters seriously contaminated.  

CAP10B - Lycoming O-360 - Leicester - 14/11/2013 (201314696)

Cylinder inner exhaust and inlet valve springs found broken.  At the aircraft's annual inspection in May 2013, one spring was found broken on nr1 cylinder (inner exhaust valve spring), this spring was replaced.  A rough running engine was reported in September and on inspection, another spring was found broken. The owners then requested all springs to be changed and during this maintenance it has been discovered that there are now eight broken springs. The aircraft had completed 16 hrs since the Annual Inspection and a total of 36 hrs since overhaul when the cylinder assemblies were new (Oct 2011).  

Cessna 172 - Lycoming O-320 - Cranfield - 17/08/2013 (201310564)

PAN declared due to severe control difficulty.  At top of climb, the pilot pushed the control column forward to speed up and level for the cruise then discovered that, whatever position the trim wheel was put in, the aircraft continued to climb.  Trim was recycled several times with no effect and a nose up attitude prevailed.  A PAN call was made and the pilot managed to stabilise the aircraft and make a direct return.  

Grob 115 - Lycoming O-360 - Bournemouth/Hurn - 13/11/2013 (201314817)

LH elevator flange found cracked.  During inspection of flying control bracket the engineer carried out a dye penetrant test which confirmed the flange was cracked.  Fleet check to be carried out of visual inspection of LH and RH flange before next flight.  Manufacturer have requested the defective part is returned for investigation.  

Percival P40 Prentice - Gipsy Queen 30 - St. Mawgan - 29/07/2013 - (201311088)

During taxi, a loud bang was heard and the aircraft swung to the left.  Full opposite controls, rudder and brake had no effect so the engine was stopped and the aircraft was left blocking the runway. Passengers were evacuated and escorted back to the apron and the aircraft was returned to hangar.  Engineering investigation found that the RH wheel had cracked, the tyre had come off and punctured the tube and the wheel was locked up against the undercarriage leg.  An old crack along the groove for the steel securing ring had progressed to a point where the failure had occurred.  A similar crack was found on the LH wheel. Replacement wheels were sourced, overhauled and NDT tested.  The maintenance programme has been amended to include inspections and NDT testing at each annual inspection.  (GASCo Comment: Useful advice for all who operate similar classic aircraft).    

Remos GX - Rotax 912 - Battle - 6/11/2013 (201315428)

Damaged (burnt) coolant hose due to the required gap between the hose and exhaust pipe being unachievable.  The coolant hose running from radiator to pump had been in contact with the hot rear exhaust pipe and caused a burn which had almost penetrated through the hose.  It was not in this condition when inspected in March 2013.  A new hose has been sourced from the manufacturer (P/N 100877) which is larger in diameter than the original. The gap between the engine and the exhaust, through which this hose must pass, is very small and the required gap of ½ in between the exhaust pipe and the coolant hose cannot be achieved.  Remos acknowledge this problem with Remos G3 (SD043) but SD refers to earlier smaller OD hose and not GX model.  Total hours 271.   

Piper PA32 - Lycoming 540 - Bidford Gliding Club - 03/09/2013 (201311336)

Precautionary landing made following smoke and loss of power.  A burning smell was noticed which it was thought could have been due to a couple of fires on the ground. There were no indicated problems but the pilot thought it would be safer to head back towards the home base.  Shortly after turning back, a significant amount of paint was seen peeling from around the oil filler door on the cowling.  This was followed by a drop in power and a few seconds later the aircraft oil inspection door popped open.  An immediate decision was made to land at the nearest airfield which was close by.  On inspection, it was found that the exhaust had a hole blown in the top very close to the cowling.  This had started to burn through the heat proof shield causing the paint to peel and the cowling to distort, thereby causing the oil inspection door to come open.  

Vulcanair (Partenavia) P68 - Lycoming O-360 - Hawarden - 07/11/2013 (201314311)

Engine mounting upper brackets cracked and corroded.  Visual cracks emanating from rivet holes on the vertical face were discovered on three out of four of the upper mounting brackets.  On removal, it was noted that exfoliation corrosion is developing on the upper corners of the brackets. The areas of corrosion were not visible on the initial inspection but became apparent on removal of upper nacelle and firewall.  All upper mounting brackets replaced iaw SB70 Rev 2. A discrepancy was discovered in the documentation; the drawings do not show the two rivet holes where the cracks have developed.  This was queried with the manufacturer who insist that the rivet holes were correct for this tailfin. 


Bell  206 - Allison 250 - Nr Ashton Court, Bristol - 11/08/2013 (201310514)

Smoke from overheated lead acid battery.  Smoke was detected by the pilot during the final phase of flight but as nothing was visible on the aircraft it was thought to be from an outside source such as a bonfire.  However, once the aircraft had landed and passengers exited, the ground crew noticed smoke coming from the area of the battery cover. Aircraft shut down and all electrics switched off.  Engineer inspection revealed the battery to be in a seriously hot condition.  It was quickly disconnected and allowed to cool. AOG until a new battery was installed.  Reporter notes that the lead acid battery fit does not have any form of "Hot Battery" warning within the CWP of the helicopter and would seem to be a shortfall within the electrical safety system. The manufacturers will also be contacted regarding the incident. 

Eurocopter EC135 - Turbomeca Arrius - Boreham, Essex - 29/08/2013 (201311015)

Incorrect fitting stay fitted to the transmission cowling.   A subsequent report from the quality engineer stated the illustrated parts catalogue was misleading.  The correct part was fit ted in replacement.  

Eurocopter EC135  - Clipper Field Platform - 06/11/2013 (201314322)

During the initial climb shortly after take-off, after autopilot was engaged, the aircraft unexpectedly reduced speed and descended.  Manual control was regained and the flight continued.  Subject to AAIB Field Investigation. 

MD 900 - P & W - Carr Gate - 11/11/2013 (201314507)

Cracked downlink actuator.  The downlink arm was being retracted iaw pre-landing checks when the observer reported that the arm did not appear to have full retracted.  Second attempt was made with the same result, this time it was seen to be wobbling a little more than usual.  After an uneventful landing, an inspection was carried out and substantial cracks were found in the actuator arm where that arm adjoins a plate at the actuator end.



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