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June 3, 2017 · Paul R Seipt Sonex Undesignat · N255BZ

Garfield, WA

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
June 3, 2017
Injury Outcomes
No injuries (1 uninjured)
Location
Garfield, WA
Aircraft
Paul R Seipt Sonex Undesignat (2016)
Tail Number
N255BZ
Operator
Seipt Paul R
Injuries
None
Aircraft Damage
Substantial
NTSB Number
WPR17LA119

The pilot reported that, during cruise flight, the airplane began vibrating, followed by a loud bang. The pilot saw the propeller separate from the airplane and he subsequently performed a forced landing to a road. During the landing roll, the left wing impacted a guy wire, resulting in substantial damage to the left wing. Postaccident examination revealed that the crankshaft separated at the forward main bearing journal. The area of separation exhibited beach marks propagating from the woodruff key area throughout most of the separated surface area. The flywheel mounting flange attached to the crankshaft and the flywheel mating surface showed material deformation at several screw holes and two fractured screw shafts that remained in their holes in the mount. A 1/4-inch wide area of fretting was noted around the outer circumference of the mounting flange and flywheel mating area. The trigger shaft, which was attached to the flywheel, displayed scuffing and material deformation at the locations of the flywheel mounting flange screw heads. The pilot/builder reported that he found no torque values in the manufacturer’s assembly manual during assembly of the flywheel and he was uncertain of the torque that he applied to the screws, although he thought that it was sufficient. It is likely that he did not adequately torque the screws during installation of the flywheel, which allowed the screws to loosen over time, resulting in elongation of the screw holes and fretting on the flywheel mounting flange and flywheel mating surface. The loose flywheel assembly would have increased vibration throughout the engine, along with torsional loads that ultimately resulted in the separation of the forward crankshaft and propeller assembly. A Federal Aviation Administration (FAA) Advisory Circular shows the recommended torque to be used for a specified fastener. Builders can also contact the manufacturer, who can supply them with a general torque table. The maintenance history of the airplane was not obtained during the investigation.

NTSB Probable Cause

The pilot’s improper torque of screws that attached the flywheel mounting flange to the crankshaft during engine assembly, which resulted in heavy vibrations and the subsequent in-flight loss of the propeller.

Full Narrative

On June 3, 2017, about 1130 Pacific daylight time, an experimental, amateur-built Sonex, N255BZ, was substantially damaged when it was involved in an accident near Garfield, WA. The private pilot was not injured. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 personal flight. The pilot, who was also the builder of the airplane, reported that, during cruise flight at 4,000 ft mean sea level, he experienced an increasing vibration followed by a loud bang. He subsequently saw the propeller separate from the airplane and he performed a forced landing to a paved road. During the landing roll, the airplane impacted a power pole guy wire, resulting in substantial damage to the left wing (see Figure 1). Figure 1. Accident site. Examination of the airplane revealed that the propeller assembly and forward section of the crankshaft separated from the engine. The propeller and separated crankshaft section were not located. An examination of the engine crankcase and crankshaft was conducted at the aircraft manufacturer. The crankshaft separation surface was located at the forward main bearing journal and exhibited beach marks propagating from the woodruff key slot and extending through most of the separated surface area. (see Figure 2.) The flywheel mounting flange attached to the crankshaft and the flywheel mating surface showed material deformation at several screw holes, and two fractured screw shafts remained in their holes in the mount. (see Figure 3.) A 1/4-inch area of fretting was also noted around the outer circumference of the mounting flange and flywheel mating area. The trigger shaft, which is attached to the flywheel, displayed scuffing and material deformation at the locations of the flywheel mounting screw heads. Figure 2. Crankshaft separation surface area. Figure 3. Flywheel mounting flange. The pilot reported that he found no torque values in the manufacturer’s assembly manual during assembly of the flywheel. He was uncertain of the torque that he applied to the screws, although he thought that it was sufficient. The pilot further reported that it is his common practice to apply Loctite to all critical fasteners, and he could not specifically remember adding it to the fasteners during the assembly. According to the AeroVee 2.0 Assembly Manual, the trigger shaft is installed on the flywheel with four screws and Loctite 242 applied to the screw threads. No torque value is stated in this step. The flywheel and flywheel mounting flange are preassembled for the engine kit. Federal Aviation Administration (FAA) Advisory Circular 43-13-1B Table 7-1 shows the recommended torque to be used for a specified fastener. Builders can also contact the manufacturer, who can supply them with a general torque table. The maintenance history of the airplane was not obtained during the investigation.

Flight

Event TypeAccident
Event Time11:30 PDT
Nearest Airport0nm
Flight Plan FiledNone
Flight Plan ActivatedNo
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftPaul R Seipt Sonex Undesignat
Tail NumberN255BZ
Aircraft CategoryAir
DamageSubstantial
OperatorSeipt Paul R
Operating RulePart 91
Engines1
Engine TypeReciprocating
Engine DetailsAerovee · 2180 · Reciprocating · 80
Seats2

People & Injuries

Injury SummaryNo injuries (1 uninjured)
Fatal0
Serious0
Minor0
Uninjured1
Total1
Crew 1Age 70 · None · None

Conditions

ConditionsVMC
LightDaylight
Wind180° @ 8 kt
Visibility10 sm
CeilingNone
Temperature / Dew Point50
Altimeter29.95 inHg
Observation Time17:53
Weather SourceWFAC

Appendix: Source Data