Why Cant We Make Cylinders?

Every so often, it becomes apparent the general aviation industry suffers from some kind of systemic problem affecting its underlying infrastructure. A few years ago, first Continental and then Lycoming discovered issues with new crankshafts. A few years before that, it was Cessnas failure to properly prepare its new airplanes for a different paint technology, which resulted in widespread corrosion until they were stripped and properly repainted. Now, its cylinders. And its nothing new, either. In 2004, some 2000 cylinders manufactured by Engine Components, Inc. (ECi), were the target of an airworthiness directive (AD). Another AD, effective September 9, 2009, targets an estimated 8000 Superior Air Parts, Inc. (SAP) cylinders installed on big-bore Continental engines. And in July, Continental was forced to revise a recent service bulletin adding more cylinders to a recall program it established in February. To its credit, Continental is replacing cylinders subject to the new service bulletin at its expense. (Full disclosure: My airplane is equipped with SAP cylinders subject to the new AD.)

Key Takeaways:

• The general aviation industry frequently suffers from recurring systemic infrastructure problems, with aircraft cylinders currently exhibiting widespread design and manufacturing issues.
• Numerous cylinder manufacturers, including ECi, Superior Air Parts, and Continental, have faced Airworthiness Directives (ADs) or recall programs over the past decade due to various defects.
• The author argues that the larger problem is the industry's persistent failure to resolve fundamental design and quality control flaws in mature components, despite decades of experience.
• This ongoing unreliability and lack of quality mastery are seen as self-inflicted wounds contributing to the decline in pilot training and retention within general aviation.

Key takeaways sponsored by Aviator Pro | Start Your Training ->

See a mistake? Contact us.