---------------------------------------------------------- KIS-List Digest Archive --- Total Messages Posted Tue 06/12/18: 5 ---------------------------------------------------------- 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 _____________________________________ Time: 04:21:43 AM PST US From: pastormac@comcast.net Subject: Re: KIS-List: 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 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 _____________________________________ Time: 04:29:34 AM PST US From: Galin Hernandez Subject: Re: KIS-List: 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, 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. > > > ------------------------------ > [image: Avast logo] > > This email has been checked for viruses by Avast antivirus software. > www.avast.com > > <#m_-3988576661753184916_DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2> > ________________________________ Message 3 _____________________________________ Time: 04:52:38 AM PST US From: Alfred Rosa Subject: Re: KIS-List: 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, 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 _____________________________________ Time: 05:45:37 AM PST US Subject: Re: KIS-List: Control Surface Hinge Failure - KIS4 From: Robert Reed 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 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, 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 >> >> ________________________________ Message 5 _____________________________________ Time: 06:26:21 AM PST US Subject: Re: KIS-List: Control Surface Hinge Failure - KIS4 From: Keith.Miller@esa.int dGhhbmtzIGZvciB0aGUgaGVhZHMgdXAgb24gdGhpcyBvbmUgLA0KDQogMjAgIG9kZCB5ZWFycyBh Z28gLCBteSBpbnNwZWN0b3IgaW5zaXN0ZWQgdGhhdCBJIGZpdCAzIGhpbmdlcyBvbiB0aGUNCnZl cnRpY2FsIHN0YWJhbGl6ZXIgICBqdXN0IGluIGNhc2UgdGhpcyBldmVyIGhhcHBlbmVkLCBpIHRo b3VnaHQgaXQgd2FzIGJlaW5nDQpvdmVyIGNhdXRpb3VzICBzaW5jZSB0aGVzZSBhcmUgYWlyY3Jh ZnQgc3BlYyBoaW5nZXMgICEhLCBub3cgSSBrbm93IHdoeSAsIGFuZA0KSSByZWdyZXQgbm90IGRv aW5nIHRoaXMgb24gYWxsIHRoZSBjb250cm9sIHN1cmZhY2VzDQooU2VlIGF0dGFjaGVkIGZpbGU6 IERTQ0YwMDc0LmpwZykNCg0KUExFQVNFIE5PVEU6ICAgIHRoZSAxMiAgaG9sZXMgaW4gZWFjaCBo 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