Today's Message Index:
----------------------
1. 04:21 AM - Re: Control Surface Hinge Failure - KIS4 (pastormac@comcast.net)
2. 04:29 AM - Re: Control Surface Hinge Failure - KIS4 (Galin Hernandez)
3. 04:52 AM - Re: Control Surface Hinge Failure - KIS4 (Alfred Rosa)
4. 05:45 AM - Re: Control Surface Hinge Failure - KIS4 (Robert Reed)
5. 06:26 AM - Re: Control Surface Hinge Failure - KIS4 (Keith.Miller@esa.int)
Message 1
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Subject: | Re: Control Surface Hinge Failure - KIS4 |
Hi Galin,
Thanks for the heads up!! So glad you=99re ok!!
To our success, Stephen McIntosh
> On Jun 11, 2018, at 7:03 PM, Galin Hernandez <galinhdz@gmail.com> wrote:
>
> For a while now I noticed that after lubricating my KIS4 control surface h
inges 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 pushe
d out by the air stream. But during the recently completed Condition Inspect
ion, the A&P I used noticed a dark =9Cpowder-like=9D substance a
round all the control surface hinges. He indicated it was aluminum powder wh
ich is a sign of the hinges slowly wearing out. Since my airplane is 17yrs o
ld 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 n
othing 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 n
ot normal, I aborted the flight and immediately returned to St. Augustine. O
nce in my hangar I found that the top rudder hinge had come loose, the pin i
nside the hinge had broken and had somehow fallen out. The rudder was being h
eld 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 n
o 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 t
he pin inside the hinge. I have attached photos of the bottom hinge which sh
ows some of the dark =9Cpowder-like=9D substance.
>
> So if you see a dark =9Cpowder-like=9D substance around your h
inges which become dirty watery streaks after lubrication, check the hinges o
f your control surfaces. Be very thorough with your inspection and replace t
he hinges if there is any question about their integrity. I am now in the pr
ocess of replacing all the hinges of my airplane, not just for the rudder bu
t both the ailerons and elevators. Be extra cautious with this since this ca
n easily become a serious safety of flight issue.
>
> <20180611_144317[1].jpg>
> <20180611_182007[1].jpg>
Message 2
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Subject: | Re: Control Surface Hinge Failure - KIS4 |
*"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 aluminum and stainless in close contact with each other."*
Mike - I consider myself fairly good at electronic things but admit I am
poor, at best, with materials so I really don't know. The hinges are
original from before 2001 and I know they are extensively used in certified
airplanes but it could be. I imagine others here, much better qualified
with materials, will provide good input.
On Mon, Jun 11, 2018 at 11:13 PM, <mike@vision499.com> wrote:
> 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 betwee
n
> the different metals, I know that on our boat we have a problem with
> aluminum 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
@
> matronics.com] *On Behalf Of *Galin Hernandez
> *Sent:* June 11, 2018 4:04 PM
> *To:* kis-list@matronics.com
> *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 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.
>
>
> ------------------------------
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>
Message 3
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Subject: | Re: Control Surface Hinge Failure - KIS4 |
I foresaw the problem of wear on the aluminum hinges and championed the use o
f stainless steel hinges. I couldn=99t find ss hinges of sufficiently
tight tolerances so instead used longer lengths of the aluminum ones. My a
ilerons, elevator, and rudder had full length hinges. The flaps were getting
full length (in several pieces for greater flexibility) hinges also. Of co
urse I don=99t know how it all worked out since I sold the project bef
ore it ever flew.
I would recommend installing new hinges every so many hours of flying time.
Al ROSA
> On Jun 11, 2018, at 11:13 PM, <mike@vision499.com> <mike@vision499.com> wr
ote:
>
> Thanks for the heads up Galin,
>
> I remember speaking to Vance and Rich about lubricating the hinges and bot
h 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@ma
tronics.com] On Behalf Of Galin Hernandez
> Sent: June 11, 2018 4:04 PM
> To: kis-list@matronics.com
> Subject: KIS-List: Control Surface Hinge Failure - KIS4
>
> For a while now I noticed that after lubricating my KIS4 control surface h
inges 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 pushe
d out by the air stream. But during the recently completed Condition Inspect
ion, the A&P I used noticed a dark =9Cpowder-like=9D substance a
round all the control surface hinges. He indicated it was aluminum powder wh
ich is a sign of the hinges slowly wearing out. Since my airplane is 17yrs o
ld 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 n
othing 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 n
ot normal, I aborted the flight and immediately returned to St. Augustine. O
nce in my hangar I found that the top rudder hinge had come loose, the pin i
nside the hinge had broken and had somehow fallen out. The rudder was being h
eld 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 n
o 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 t
he pin inside the hinge. I have attached photos of the bottom hinge which sh
ows some of the dark =9Cpowder-like=9D substance.
>
> So if you see a dark =9Cpowder-like=9D substance around your h
inges which become dirty watery streaks after lubrication, check the hinges o
f your control surfaces. Be very thorough with your inspection and replace t
he hinges if there is any question about their integrity. I am now in the pr
ocess of replacing all the hinges of my airplane, not just for the rudder bu
t both the ailerons and elevators. Be extra cautious with this since this ca
n easily become a serious safety of flight issue.
>
>
>
>
> This email has been checked for viruses by Avast antivirus software.
> www.avast.com
>
>
Message 4
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Subject: | Re: Control Surface Hinge Failure - KIS4 |
I didn=99t use full length hinges but I more than doubled the size tha
t was called for and placed the mounting screws at strongest point of the hi
nge every inch. The screws don=99t align but the heads are covered any
way. I just didn=99t believe the hinges were robust enough based on pl
ans. I also reinforced the hinge pads with additional fiberglass pads.
On the other hand I am still not finished either.
Bob Reed
Sent from my iPhone
> On Jun 12, 2018, at 6:49 AM, Alfred Rosa <fredorosa@gmail.com> wrote:
>
> I foresaw the problem of wear on the aluminum hinges and championed the us
e of stainless steel hinges. I couldn=99t find ss hinges of sufficien
tly tight tolerances so instead used longer lengths of the aluminum ones. M
y ailerons, elevator, and rudder had full length hinges. The flaps were gett
ing full length (in several pieces for greater flexibility) hinges also. Of
course I don=99t know how it all worked out since I sold the project b
efore it ever flew.
> I would recommend installing new hinges every so many hours of flying time
.
> Al ROSA
>
>> On Jun 11, 2018, at 11:13 PM, <mike@vision499.com> <mike@vision499.com> w
rote:
>>
>> Thanks for the heads up Galin,
>>
>> I remember speaking to Vance and Rich about lubricating the hinges and bo
th 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 betwee
n the different metals, I know that on our boat we have a problem with alumi
num 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@m
atronics.com] On Behalf Of Galin Hernandez
>> Sent: June 11, 2018 4:04 PM
>> To: kis-list@matronics.com
>> Subject: KIS-List: Control Surface Hinge Failure - KIS4
>>
>> For a while now I noticed that after lubricating my KIS4 control surface h
inges 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 pushe
d out by the air stream. But during the recently completed Condition Inspect
ion, the A&P I used noticed a dark =9Cpowder-like=9D substance a
round all the control surface hinges. He indicated it was aluminum powder wh
ich is a sign of the hinges slowly wearing out. Since my airplane is 17yrs o
ld 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 n
othing 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 n
ot normal, I aborted the flight and immediately returned to St. Augustine. O
nce in my hangar I found that the top rudder hinge had come loose, the pin i
nside the hinge had broken and had somehow fallen out. The rudder was being h
eld 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 n
o 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 t
he pin inside the hinge. I have attached photos of the bottom hinge which sh
ows some of the dark =9Cpowder-like=9D substance.
>>
>> So if you see a dark =9Cpowder-like=9D substance around your h
inges which become dirty watery streaks after lubrication, check the hinges o
f your control surfaces. Be very thorough with your inspection and replace t
he hinges if there is any question about their integrity. I am now in the pr
ocess of replacing all the hinges of my airplane, not just for the rudder bu
t both the ailerons and elevators. Be extra cautious with this since this ca
n easily become a serious safety of flight issue.
>>
>>
>>
>>
>> This email has been checked for viruses by Avast antivirus software.
>> www.avast.com
>>
>>
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Subject: | Re: Control Surface Hinge Failure - KIS4 |
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