Corroded, Cracked

During inspection, the forward upper l/h wing attach point was found to have corrosion on the wing attach fitting (p/n 08113507). After removing the upper wing-fuselage fairing, inspection revealed intergranular corrosion on the fitting, and severe rust on the mounting bolt heads. The fitting was replaced due to the severity of the corrosion. Probable cause of this corrosion is the fuselage-wing fairing not being sealed properly in the area above the fitting.

Key Takeaways:

• Structural issues were identified across several aircraft, including a cracked elevator pulley support in a Cessna 208B, corroded wing attach fittings in a Cessna 335 (due to improper sealing), and cracked nacelle angles in a Piper PA-44-180 (suspected fatigue).
• A Continental TSIO-520C engine experienced catastrophic failure just 35 hours after overhaul, exhibiting extreme heat damage with an undetermined cause.
• New ECI cylinders on a Continental GTSIO-520-H engine suffered multiple valve guide failures after only 384 hours, resulting in engine contamination, despite initially subtle operational indications.

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