RV Accident Reports

Updated January 3rd, 1995

I logged into the FAA Safety computer BBS and downloaded the RV Accident Reports. Please note that reports have NOT been confirmed or verified by FAA. Reports are furnished solely for information. Below is a list of how the information is organized in this document:

1. FAA Safety BBS
2. Submitted Accident reports by RV-6, RV-4 and RV-3.

John

Please pass the bulletin board number around to others.
Encourage its use to improve safety!
The FAA Safety BBS number is 1-800-426-3814

SYSOP : Ben Morrow
FAA, ACE-103
601 E. 12th. St.
Kansas City, MO. 64106
816-426-5954
INTERNET: CVKR12A@PRODIGY.COM

Please note that reports have NOT been confirmed or verified by FAA. Reports are furnished solely for information. Following suggestions by submitters should be done with CAUTION.

DATE :910330
AIRCRAFT MODEL : RV-6
ENGINE MAKE/MODEL : Lycoming E2A
PROPELLER MAKE/MODEL : Pacesetter 200
COMPONENT MAKE/MODEL :
PARTNAME : Exhaust Pipe PARTNUMBER :
PART LOCATION : #4 cyl.& "Y" PART CONDITION : Cracked
REMARKS :
The exhaust pipes had cracked twice at the #4 cylinder. The second time was in flight; a safe by loud landing was made and it was found that the pipe had completely separated and had also cracked at the "Y" connection. The pipes were braced from an oil pan bolt directly down to the pipes. The manufa- cturer stated that the brace should have gone to the rear of the pipes instead of straight down to the pipes.

DATE :910624
AIRCRAFT MODEL : RV-6
ENGINE MAKE/MODEL : Lycoming E2A
PROPELLER MAKE/MODEL : Pacesetter 68x66
COMPONENT MAKE/MODEL : Alan Tolle
PARTNAME : Exhaust System PARTNUMBER :
PART LOCATION : #4 Cylinder PART CONDITION : Broke
REMARKS :
#383 cont. After repair by Alan Tolle by adding a flexible sleeve at the #4 cylinder. The exhaust system was braced as recommended. I ran a brace from an oil pan bolt to the rear end of each pipe directly in front of the firewall. After about 20 flight hours I have found no further cracks or breaks; the sleeve at the #4 cylinder seems to have given some flexibility to the system. Always check the tail pipes before each flight, any grinding of metal, unusual noise or excessive movement would be cause for further investigation.

DATE :910415
AIRCRAFT MODEL : RV-6
ENGINE MAKE/MODEL : Lycoming O360A4M
PROPELLER MAKE/MODEL : Pacesetter 70X7130
COMPONENT MAKE/MODEL : Allan Tolle
PARTNAME : Stainless PARTNUMBER :
PART LOCATION : #4 Cylinder PART CONDITION : Broke off
REMARKS :
The #4 cylinder pipe broke completely off at 12 hours TTSN. Repaired and rebroke at 30 hours TTSN. Rewelded all welds and added small reinforcement patches while flooding interior of pipes with argon. There is now 160 hours on the aircraft with no further problems. The pipes are unsupported between the mounting flanges.

SYSTEM : X RECORD # : 608
DATE :930303
AIRCRAFT MODEL : RV-6
ENGINE MAKE/MODEL : LYC O320-E3D
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : ALLAN TOLLE
PARTNAME : EXHAUST PIPE PARTNUMBER :
PART LOCATION : #4 CYL. "Y" PART CONDITION : CRACKED
REMARKS :
CRACK OCCURRED AT THE "Y" JUNCTION BELOW THE #4 CYLINDER, THIS OCCURRED EVEN THOUGH I HAVE BALL JOINTS WELDED INTO THE PIPES AT THE #4 AND #1 CYLINDER STUBS. MY OPINION IS THAT BRACING THESE PIPES FROM THE ENGINE IS A POOR IDEA AND THAT THE PIPES THEMSELVES ARE POORLY MADE. THE MATERIAL SHOULD BE THICKER AND EACH LEG BELOW THE CYLINDERS MUST HAVE SOME EXPANSION SLIP OR A BALL JOINT.

DATE :930425
AIRCRAFT MODEL : RV-6
ENGINE MAKE/MODEL : LYC O-320E2D
PROPELLER MAKE/MODEL : SENSENICH
COMPONENT MAKE/MODEL :
PARTNAME : FUEL PARTNUMBER :
PART LOCATION : PART CONDITION : VAPOR LOCK
REMARKS :
AFTER A SHORT FLIGHT ON MOGAS THE PLANE WAS REFUELED WITH 80/87 AVGAS AND ON TAKEOFF THE ENGINE QUIT COLD AT ABOUT A SPEED OF 50 MPH JUST BEFORE ROTATION. ABORTED TAKEOFF, AND SUBSEQUENT ENGINE START WAS UNEVENTFUL. OAT WAS 94F AND VAPOR LOCK WAS THE MOST PROBABLE CAUSE. HOT STARTS ON MOGAS ON A HOT DAY ARE A VERY POOR IDEA.

SYSTEM : X RECORD # : 726
DATE :941128
AIRCRAFT MODEL : RV-6A
ENGINE MAKE/MODEL : LYC O320
PROPELLER MAKE/MODEL : PACESETTER
COMPONENT MAKE/MODEL : TOOLE
PARTNAME : EXHAUST PARTNUMBER :
PART LOCATION : PART CONDITION : FAILED
REMARKS :
The exhaust system failed on three different occasions and was rewelded. The system broke completely off at the #4 cylinder twice and at the #1 cylinder once. Made for a very loud flight, but a safe landing. Replaced the exhaust system with one from Highcountry and have not experienced any problems so far.

SYSTEM : A RECORD # : 255
DATE :901121
AIRCRAFT MODEL : RV4
ENGINE MAKE/MODEL : LYC
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : BRACKETS PARTNUMBER :
PART LOCATION : FUSELAGE TO ENGINE PART CONDITION : CRACKED
REMARKS :
ALL FOUR OF THE FUSELAGE-ENGINE MOUNT BRACKETS CRACKED CAUSING A SERIOUS SAFETY PROBLEM. SUBMITTER IS AWARE OF TWO OTHER RV4'S WHICH HAVE HAD THE SAME PROBLEM.

SYSTEM : P RECORD # : 256
DATE :900721
AIRCRAFT MODEL : RV4
ENGINE MAKE/MODEL : LYC O320E2A
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : BOLTS PARTNUMBER :
PART LOCATION : PROP PART CONDITION : LOOSE
REMARKS :
THE PROPELLER BOLTS WERE NOT TORQUED TO SPECS. PROP BECAME LOOSE AND SEVERE VIBRATION DEVELOPED.

SYSTEM : P RECORD # : 450
DATE :910623
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : Lycoming O320-B3B
PROPELLER MAKE/MODEL : Lectro Prop 216/318
COMPONENT MAKE/MODEL : Lectro Prop 216/318
PARTNAME : Blades PARTNUMBER :
PART LOCATION : Propeller PART CONDITION : Failed
REMARKS :
Both blades failed at the hub in flight. The hubs with parts of the blades still in the hubs were examined and found to have failed primarily due to a hydrolysis interaction between the wood and the adhesive caused by excess moisture and heat. Hydrolysis is a chemical decomposition process of the wood and glue relationship.

SYSTEM : O RECORD # : 473
DATE :910915
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : Lycoming O320A
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : Acft. Metal Prod Stainless
PARTNAME : Hose PARTNUMBER : 762506-6
PART LOCATION : oil cooler PART CONDITION : Failed
REMARKS :
Installed AMP stainless hose, per PA38 connected oil cooler left baffle to rear case with hoses. 1/2 inch hose failed at end fitting in flight, causing engine failure. Purchased from Aircraft Spruce, claims never failed before. There is AD on hose for twist. I? removed three other hoses on aircraft and no preload was found.

SYSTEM : A RECORD # : 501
DATE :911204
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : Lycoming O320D1A
PROPELLER MAKE/MODEL : Sterba 66x68
COMPONENT MAKE/MODEL :
PARTNAME : Brackets PARTNUMBER :
PART LOCATION : Front Corner PART CONDITION : Cracked
REMARKS :
All four steel corner brackets that carry the engine mount loads into the fuselage cracked after a time in service of 60 to 120 hours. The aircraft had been operated mostly from a grass and dirt strip. Reinforcing the brackets with Van's new heavier parts plus an additional layer of 0.070 steel, solved the problem. There has been no further cracking as of 500+ hours.

SYSTEM : E RECORD # : 538
DATE :920420
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : Lycoming O360-A4A
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : Lewis Aviation
PARTNAME : Induct.Air Box PARTNUMBER :
PART LOCATION : PART CONDITION : Failed
REMARKS :
The butterfly valve which switches air from outside to alternate heat source is held on by three 256 screws which are too small. The screws failed causing the valve to fall against carburator intake and restrict the air flow to the carb. Also caused a loss of carb heat.

SYSTEM : X RECORD # : 539
DATE :920421
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : Lycoming O360-A4A
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : Toole
PARTNAME : Exh. Manifold PARTNUMBER :
PART LOCATION : PART CONDITION : Cracked
REMARKS :
The exhaust manifold failed due to cracks on three different occasions after welding and bracing in accordance with the manufacturer's recommendations. The part was improperly formed to fit on the O360 and rubbed on the oil pan where it crossed over and was wearing away the oil pan. Replaced with two separate exhaust stacks which were made of heavier steel and they have not failed in 600 hours. In conversations with other RV-4 owners, they indicate that they have had similar problems.

SYSTEM : F RECORD # : 562
DATE :920709
AIRCRAFT MODEL : RV4
ENGINE MAKE/MODEL : LYC O320
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : AC
PARTNAME : FUEL PUMP PARTNUMBER : 41271D197
PART LOCATION : ENGINE PART CONDITION : FAILED
REMARKS :
FUEL PUMP FAILED ON TAKEOFF. PILOT WAS UNABLE TO RESTART THE ENGINE. INVESTIGATION REVEALED THAT THE SPRING ON ONE OF THE CHECK VALVES FAILED.

SYSTEM : A RECORD # : 622
DATE :930324
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL : LYC 0320B2B
PROPELLER MAKE/MODEL : HARTZELL
COMPONENT MAKE/MODEL :
PARTNAME : BRACKET PARTNUMBER :
PART LOCATION : UPPER LEFT PART CONDITION : FAILED
REMARKS :
THE UPPER LEFT ENGINE/FIREWALL BRACKET FAILED. DISCOVERED AT 300 HOURS THE UPPER RIGHT ENGINE/FIREWALL BRACKET WAS CRACKED. LOWER BRACKETS CHECKED OK. THESE WERE THE FIRST DISIGN VERSION BRACKETS. REPLACED WITH THE 1993 VERSION BRACKETS. AIRCRAFT IS USED FOR ONLY OCCASIONAL MODERATE AEROBATICS. NO HISTORY OF HARD LANDINGS OR OF ACCIDENTS.

SYSTEM : O RECORD # : 701
DATE :940716
AIRCRAFT MODEL : RV-4
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : Oil Cooler PARTNUMBER :
PART LOCATION : Front engine PART CONDITION : cracked
REMARKS :
Upon inspection before flight, the oil cooler mounting bracket welds were found completely broken and the oil cooler held in by only the silicone sealant. The aircraft had less than 20 hours when discovered. Upon replacement the cooler has shown no other damage.

SYSTEM : F RECORD # : 25
DATE :900806
AIRCRAFT MODEL : Vans RV-3
ENGINE MAKE/MODEL : Lycoming O320E2D
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : Engine PARTNUMBER :
PART LOCATION : PART CONDITION : Failed
REMARKS :
The engine lost power on takeoff. OAT 107. Initial cause determined was probable vapor lock.

SYSTEM : F RECORD # : 245
DATE :890721
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : ENGINE PARTNUMBER :
PART LOCATION : PART CONDITION : FAILED
REMARKS :
USING MOGAS. VAPOR LOCKED AND ENGINE FAILED.

SYSTEM : M RECORD # : 246
DATE :900000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL : LYC O290D2
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL : BENDIX S4LN21
PARTNAME : IMPULSE COUPLING PARTNUMBER :
PART LOCATION : MAGNETO PART CONDITION : SPRING BROKE
REMARKS :
AIRCRAFT STARTED OK, BUT HAD A POPPING NOISE FROM THE EXHAUST PIPES. A MAGNETO CHECK SHOWED THE LEFT MAGNETO WOULD DROP OFF 600 RPM TO 700 RPM, AND RUN ON ALL 4 CYLINDERS. A TIMING CHECK SHOWED THE LEFT MAGNETO WAS FIRING AT TDC, AND THE IMPULSE COUPLING WOULD NOT SNAP WHEN PROPPING THE ENGINE. SUBMITTER STATES CAUSE UNKNOWN, REPLACED SPRING AT OVERHAUL. SPRING HAD BROKE IN 2 PARTS ABOUT 3 INCHES FROM ONE END.

SYSTEM : A RECORD # : 247
DATE :800000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : MOUNT PARTNUMBER :
PART LOCATION : RLG ATTACHMENT PART CONDITION : DAMAGED
REMARKS :
FOUND THE ENGINE MOUNT DAMAGED AT RIGHT MAIN LANDING GEAR ATTACHMENT.

SYSTEM : E RECORD # : 248
DATE :800000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : CARB HEAT BOX PARTNUMBER : 21323
PART LOCATION : FLANGE WELDS PART CONDITION : BROKEN
REMARKS :
NO TEXT.

SYSTEM : E RECORD # : 249
DATE :810000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL : LYC IO320
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : BUTTERFLY PARTNUMBER :
PART LOCATION : AIR INTAKE PART CONDITION : LOOSE
REMARKS :
THE ENGINE QUIT DUE TO BUTTERFLY VALVE COMING LOOSE AND BLOCKING THE AIR INTAKE. SCREWS HAD NOT BEEN STAKED AND BACKED OUT.

SYSTEM : A RECORD # : 250
DATE :810000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : SPAR PARTNUMBER :
PART LOCATION : LEFT WING PART CONDITION : FAILED
REMARKS :
LEFT WING SEPARATED FROM AIRCRAFT WHEN SPAR FAILED DURING A LOW LEVER HIGH SPEED PULL UP.

SYSTEM : A RECORD # : 251
DATE :870000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL : LYC O320
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : WING SPAR PARTNUMBER :
PART LOCATION : REAR ATTACH POINT PART CONDITION : BROKEN
REMARKS :
THE AIRCRAFT WAS PERFORMING AEROBATIC MANEUVERS. WHILE IN A CLIMB,IT APPEARS THE RIGHT FUEL TANK AND FLAP DEPARTED THE AIRCRAFT, FOLLOWED BY THE WING. THE AIRCRAFT NOSED OVER AND WENT STRAIGHT INTO THE GROUND. THE CENTER OF THE RIGHT WING WAS BENT UPWARDS. THE REAR SPAR ATTACH POINT FOR THE WING WAS BROKEN. FURTHER INVESTIGATION REVEALED THAT THE REAR WING SPAR MODIFICATION WAS INSTALLED AND THE AIRCRAFT WAS APPROVED TO PERFORM AEROBATICS.

SYSTEM : A RECORD # : 252
DATE :880000
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL :
PROPELLER MAKE/MODEL :
COMPONENT MAKE/MODEL :
PARTNAME : SPAR PARTNUMBER :
PART LOCATION : FORWARD PART CONDITION : FAILED
REMARKS :
ACCORDING TO THE SUBMITTER, THE AIRCRAFT WAS OBSERVED PERFORMING A SERIES OF AEROBATIC MANEUVERS. WITNESS SAID THE AIRCRAFT WAS IN A LEFT SPIN AND WHEN THE AIRCRAFT RECOVERED, HE NOTICED THE LEFT WING WAS BENT UPWARD. THE AIRCRAFT WAS PULLED LEVEL JUST AS IT IMPACTED THE GROUND. SUBSEQUENT INVESTIGATION REVEALED THE MAIN SPAR HAD FAILED DUE TO OVERLOAD. IT IS UNKNOWN WHICH MANEUVER CAUSED THE FAILURE.

SYSTEM : A RECORD # : 253
DATE :901204
AIRCRAFT MODEL : RV3
ENGINE MAKE/MODEL : LYC O290
PROPELLER MAKE/MODEL : GREAT AMERICAN 68/71
COMPONENT MAKE/MODEL :
PARTNAME : BRACKET FUSE/ENG PARTNUMBER : WD-302L 7 R
PART LOCATION : FUSELAGE 9(INSIDE) PART CONDITION : CRACKED
REMARKS :
AIRPLANE HAS APPROXIMATELY 200 HOURS AND THE BRACKETS ARE STARTING TO BREAK. THIS AREA NEEDS IMMEDIATE ATTENTION BY ALL BUILDERS AND FLYERS. FOUND DURING INSPECTION.

SYSTEM : A RECORD # : 254
DATE :901116
AIRCRAFT MODEL : RV3A
ENGINE MAKE/MODEL : LYC O320E2D
PROPELLER MAKE/MODEL : GREATAMER
COMPONENT MAKE/MODEL :
PARTNAME : SPAR ATTACH POINT PARTNUMBER :
PART LOCATION : REAR SPAR PART CONDITION : FAILED
REMARKS :
THE REAR SPAR ATTACH POINT FAILED. NEEDS A STRONGER REAR SPAR.

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