Corroded, Cracked

The aft canted bulkhead (p/n 2612060-5) at station 474.40 was discovered with two cracks, each approximately 1.5 inches in length. During removal, other damage was found. Both vertical stabilizer webs (p/ns 2631021-15 and 2631022-2) were replaced because of significant fretting, as was the aft bulkhead assembly (p/n 2612059-1).

Editorial Staff

Thursday, April 19, 2012 at 12:00 AM ET

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FlightSmart gives the instructor constantly updated information about a trainee pilot's strengths and weaknesses. FlightSafety International

Key Takeaways:

The article details various mechanical failures in general aviation aircraft components, including a cracked structural bulkhead, a worn fuel selector valve, and engine component damage (piston, camshaft gear).
A new modification, aileron gap seals, caused flight controls to freeze on a Piper Seneca when encountering below-freezing precipitation, demonstrating how environmental factors can create safety issues with new installations.
Contributing factors identified across incidents include long-term wear, potential manufacturing defects, and critically, non-compliance with relevant service bulletins.