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Cracked, Failed, Fractured

After takeoff on a post-inspection flight, the pilot heard a "snap" and the aircraft pitched up. Control was regained by reducing power and using elevator trim. The aircraft returned for a successful high-speed wheel landing. The elevator cable (p/n 414-187097-1) broke at the pulley above the tail wheel, at bulkhead number 14. The pulley was free to rotate but exhibited signs of wear-possibly from over-tensioning of the cable. Further inspection revealed broken cable strands in the area of its attachment to the elevator control bull wheel.

Gemini Sparkle

Key Takeaways:

  • Multiple aircraft experienced critical component failures, including an elevator cable breaking during takeoff (Beechcraft E18S) due to wear and over-tensioning, and a rudder horn cracking (Piper PA-28R-201) attributed to improper welding techniques.
  • Other incidents involved a Piper PA-31-350 fuel cell seam failing prematurely while parked, a Piper PA46-350P's cockpit window fracturing at 15,000 feet, and a Continental IO-550-B engine developing a hidden crack in its oil cooler, likely from a casting flaw or installation stress.
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Beechcraft E18S

Broken Elevator Cable

After takeoff on a post-inspection flight, the pilot heard a “snap” and the aircraft pitched up. Control was regained by reducing power and using elevator trim. The aircraft returned for a successful high-speed wheel landing.

The elevator cable (p/n 414-187097-1) broke at the pulley above the tail wheel, at bulkhead number 14. The pulley was free to rotate but exhibited signs of wear-possibly from over-tensioning of the cable. Further inspection revealed broken cable

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