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November 15, 2021 · Sonex Waiex B · N535D

Laveen Village, AZ

Overview

Report Status
Final with probable cause
Event Type
Accident
Date
November 15, 2021
Injury Outcomes
1 injury (1 minor injury)
Location
Laveen Village, AZ
Aircraft
Sonex Waiex B (2018)
Tail Number
N535D
Operator
Air-Spaces
Injuries
Minor
Aircraft Damage
Substantial
NTSB Number
WPR22LA035

The pilot reported the engine began running rough during cruise flight, and the airplane could not maintain altitude. The pilot initiated a forced landing to an airstrip and during the descent realized that he was not going to make the airstrip, so he elected to landed on the desert terrain. The airplane impacted rocks and a barbed wire fence which caused the airplane to nose over, which resulted in substantial damage to the wings, stabilizers, and ruddervators. Postaccident examination of the engine revealed that the No. 4 exhaust rocker assembly swivel housing separated from the screw body, likely due to wear of the swivel and the swivel pad housing. This wear likely occurred because of either incorrect spacing between the pad and valve, or corrosion.

NTSB Probable Cause

Failure of the rocker swivel assembly due to either wear or corrosion, which resulted in a loss of engine power.

Full Narrative

On November 15, 2021, about 1130 mountain standard time, an experimental amateur-built Sonex Waiex-B airplane, N535D, was substantially damaged when it was involved in an accident near Laveen Village, Arizona. The pilot was not injured. The airplane was operated by the pilot as a Title 14 Code of Federal Regulations Part 91 personal flight. The pilot reported that he had been flying for about 48 minutes when the engine began to run rough. He said the airplane did not have enough power to maintain altitude and he initiated a forced landing to an airstrip. The pilot realized he was not going to make the airstrip and landed on desert terrain, impacting rocks and a barbed wire fence which caused the airplane to nose over which resulted in substantial damage to the wings, stabilizers, and ruddervators. The pilot was able to exit the cabin area through the broken canopy. Examination of the airplane revealed that the No. 4 cylinder exhaust valve rocker arm swivel housing and swivel pad separated from its screw body. The screw body remained secured to the rocker arm. The swivel pad and swivel housing were found loose in the rocker cover. The swivel pad remained loose in the swivel housing and impact damage was visible on the swivel housing fracture surface. The rocker assembly for No. 3 and 4 cylinders and the separated swivel housing and swivel pad (see figure) were sent to the National Transportation Safety Board Materials Laboratory for forensic examination. The examination revealed a damaged fracture surface of the swivel housing and the screw body. The spherical outboard side of the swivel pad had a rough surface consistent with scoring and galling damage. The damage pattern had circular patterns on two sides with linear features in between, consistent with rotating contact within the swivel housing. The swivel housing had scoring and galling that mirrored the damage patterns observed on the swivel pad with a circular pattern on two sides and linear scratches between. The interior of the swivel housing had worn away, producing a space for the swivel pad to be recessed within the housing. This worn area was located near the facture surface of the swivel housing and screw body. Figure - Overall view of the rocker assembly showing the inboard side of the rocker arms including the fractured No. 4 exhaust valve adjuster. Review of the airplane’s maintenance records revealed that the engine was assembled on May 9, 2018. The last inspection was completed on October 12, 2021, with about 110 hours of engine operation since the engine had been assembled. At this time, the cylinders were torqued, and the valves were adjusted. The airplane flew another 25 hours before the accident.

Flight

Event TypeAccident
Event Time11:30 MST
Nearest AirportHangar Haciendas (0nm SSW)
Runway08/2
Runway Length2436 ft
Runway Width24 ft
Flight Plan FiledNone
Flight Plan ActivatedNo
Aircraft FireNo
Aircraft ExplosionNo

Aircraft

AircraftSonex Waiex B
Tail NumberN535D
Aircraft CategoryAir
DamageSubstantial
OperatorAir-Spaces
Operating RulePart 91
Engines1
Engine TypeReciprocating
Engine DetailsAerovee · Turbo · Reciprocating · 100
Seats2

People & Injuries

Injury Summary1 injury (1 minor injury)
Fatal0
Serious0
Minor1
Uninjured0
Total1
Crew 1Age 69 · Basc · Minor

Conditions

ConditionsVMC
LightDaylight
WindCalm
Visibility10 sm
CeilingNone
Temperature / Dew Point0 C / 0 C
Altimeter0
Observation Time11:30
Weather SourceWFAC

Appendix: Source Data