Today's Message Index:
----------------------
1. 04:05 PM - Control Surface Hinge Failure - KIS4 (Galin Hernandez)
2. 04:34 PM - Re: Control Surface Hinge Failure - KIS4 (Doug Crane)
3. 05:33 PM - Re: Control Surface Hinge Failure - KIS4 (Tim Yoder)
4. 08:13 PM - Re: Control Surface Hinge Failure - KIS4 ()
Message 1
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| Subject: | Control Surface Hinge Failure - KIS4 |
For a while now I noticed that after lubricating my KIS4 control surface
hinges with LPS2, what looked like dirty watery streaks would appear from
all the hinged areas. I thought it was just dirt loosened by the LPS2 and
pushed out by the air stream. But during the recently completed Condition
Inspection, the A&P I used noticed a dark =9Cpowder-like=9D sub
stance around
all the control surface hinges. He indicated it was aluminum powder which
is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old
and has more than 1,250hrs he recommended I consider replacing the hinges.
I
decided this would be done on my next condition inspection and thought
nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I
noticed that applying left rudder had gotten a little hard. Since this was
not normal, I aborted the flight and immediately returned to St. Augustine.
Once in my hangar I found that the top rudder hinge had come loose, the pin
inside the hinge had broken and had somehow fallen out. The rudder was
being held in place by the lower hinge and the control rod, neither of
which showed any indication of imminent failure. A full inspection of all
hinges showed no outward sign of failure to any of them, including the one
that just failed. I realized it is difficult, if not impossible to inspect
the condition of the pin inside the hinge. I have attached photos of the
bottom hinge which shows some of the dark =9Cpowder-like=9D sub
stance.
So if you see a dark =9Cpowder-like=9D substance around your hi
nges which
become dirty watery streaks after lubrication, check the hinges of your
control surfaces. Be very thorough with your inspection and replace the
hinges if there is any question about their integrity. I am now in the
process of replacing all the hinges of my airplane, not just for the rudder
but both the ailerons and elevators. Be extra cautious with this since this
can easily become a serious safety of flight issue.
Message 2
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| Subject: | Re: Control Surface Hinge Failure - KIS4 |
Great heads up. Thank you Galin.
(I'm in an Aviation Safety course right now.)
-Doug
On Mon, Jun 11, 2018, 16:07 Galin Hernandez <galinhdz@gmail.com> wrote:
> For a while now I noticed that after lubricating my KIS4 control surface
> hinges with LPS2, what looked like dirty watery streaks would appear from
> all the hinged areas. I thought it was just dirt loosened by the LPS2 and
> pushed out by the air stream. But during the recently completed Condition
> Inspection, the A&P I used noticed a dark =9Cpowder-like=9D s
ubstance around
> all the control surface hinges. He indicated it was aluminum powder which
> is a sign of the hinges slowly wearing out. Since my airplane is 17yrs ol
d
> and has more than 1,250hrs he recommended I consider replacing the hinges
.
> I decided this would be done on my next condition inspection and thought
> nothing of it.
>
>
> Today, just after departing on a VFR flight from St. Augustine to Ocala,
I
> noticed that applying left rudder had gotten a little hard. Since this wa
s
> not normal, I aborted the flight and immediately returned to St. Augustin
e.
> Once in my hangar I found that the top rudder hinge had come loose, the p
in
> inside the hinge had broken and had somehow fallen out. The rudder was
> being held in place by the lower hinge and the control rod, neither of
> which showed any indication of imminent failure. A full inspection of all
> hinges showed no outward sign of failure to any of them, including the on
e
> that just failed. I realized it is difficult, if not impossible to inspec
t
> the condition of the pin inside the hinge. I have attached photos of the
> bottom hinge which shows some of the dark =9Cpowder-like=9D s
ubstance.
>
>
> So if you see a dark =9Cpowder-like=9D substance around your
hinges which
> become dirty watery streaks after lubrication, check the hinges of your
> control surfaces. Be very thorough with your inspection and replace the
> hinges if there is any question about their integrity. I am now in the
> process of replacing all the hinges of my airplane, not just for the rudd
er
> but both the ailerons and elevators. Be extra cautious with this since th
is
> can easily become a serious safety of flight issue.
>
>
Message 3
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| Subject: | Control Surface Hinge Failure - KIS4 |
Thanks Galin.
I=99ll check my TR 1
Tim
From: owner-kis-list-server@matronics.com
<owner-kis-list-server@matronics.com> On Behalf Of Galin Hernandez
Sent: Monday, June 11, 2018 4:04 PM
Subject: KIS-List: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface
hinges with LPS2, what looked like dirty watery streaks would appear
from all the hinged areas. I thought it was just dirt loosened by the
LPS2 and pushed out by the air stream. But during the recently completed
Condition Inspection, the A&P I used noticed a dark
=9Cpowder-like=9D substance around all the control surface
hinges. He indicated it was aluminum powder which is a sign of the
hinges slowly wearing out. Since my airplane is 17yrs old and has more
than 1,250hrs he recommended I consider replacing the hinges. I decided
this would be done on my next condition inspection and thought nothing
of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala,
I noticed that applying left rudder had gotten a little hard. Since this
was not normal, I aborted the flight and immediately returned to St.
Augustine. Once in my hangar I found that the top rudder hinge had come
loose, the pin inside the hinge had broken and had somehow fallen out.
The rudder was being held in place by the lower hinge and the control
rod, neither of which showed any indication of imminent failure. A full
inspection of all hinges showed no outward sign of failure to any of
them, including the one that just failed. I realized it is difficult, if
not impossible to inspect the condition of the pin inside the hinge. I
have attached photos of the bottom hinge which shows some of the dark
=9Cpowder-like=9D substance.
So if you see a dark =9Cpowder-like=9D substance around your
hinges which become dirty watery streaks after lubrication, check the
hinges of your control surfaces. Be very thorough with your inspection
and replace the hinges if there is any question about their integrity. I
am now in the process of replacing all the hinges of my airplane, not
just for the rudder but both the ailerons and elevators. Be extra
cautious with this since this can easily become a serious safety of
flight issue.
Message 4
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| Subject: | Control Surface Hinge Failure - KIS4 |
Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and both
saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between
the different metals, I know that on our boat we have a problem with alumin
um and stainless in close contact with each other
Glad it all ended well
Mike
From: owner-kis-list-server@matronics.com [mailto:owner-kis-list-server@mat
ronics.com] On Behalf Of Galin Hernandez
Sent: June 11, 2018 4:04 PM
Subject: KIS-List: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hi
nges with LPS2, what looked like dirty watery streaks would appear from all
the hinged areas. I thought it was just dirt loosened by the LPS2 and push
ed out by the air stream. But during the recently completed Condition Inspe
ction, the A&P I used noticed a dark =9Cpowder-like=9D substanc
e around all the control surface hinges. He indicated it was aluminum powde
r which is a sign of the hinges slowly wearing out. Since my airplane is 17
yrs old and has more than 1,250hrs he recommended I consider replacing the
hinges. I decided this would be done on my next condition inspection and t
hought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I
noticed that applying left rudder had gotten a little hard. Since this was
not normal, I aborted the flight and immediately returned to St. Augustine.
Once in my hangar I found that the top rudder hinge had come loose, the pi
n inside the hinge had broken and had somehow fallen out. The rudder was be
ing held in place by the lower hinge and the control rod, neither of which
showed any indication of imminent failure. A full inspection of all hinges
showed no outward sign of failure to any of them, including the one that ju
st failed. I realized it is difficult, if not impossible to inspect the con
dition of the pin inside the hinge. I have attached photos of the bottom hi
nge which shows some of the dark =9Cpowder-like=9D substance.
So if you see a dark =9Cpowder-like=9D substance around your hi
nges which become dirty watery streaks after lubrication, check the hinges
of your control surfaces. Be very thorough with your inspection and replace
the hinges if there is any question about their integrity. I am now in the
process of replacing all the hinges of my airplane, not just for the rudde
r but both the ailerons and elevators. Be extra cautious with this since th
is can easily become a serious safety of flight issue.
---
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