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Cracked, Loose, Failed

The forward outboard, lower wing spar caps were found cracked. The cracks-on both left and righthand assemblies-radiated out from the fourth Huck rivet forward, passing through the wing attach hinge. This aircraft was inspected 15 months /404.2 hours ago by eddy current. No cracks were found at that time. Wing lower spar cap part numbers: l/h: 000-110012-1; r/h: 000-110012-2.

Streams coursing across the New Jersey wetlands. Jonathan Milne/Courtesy Lighthawk
Gemini Sparkle

Key Takeaways:

  • Multiple aircraft models, including Beechcraft King Air and Piper Seminole, experienced structural failures in critical components (cracked wing spar caps, cracked nose cone spar).
  • The effectiveness and compliance of maintenance inspections are highlighted as critical, with previously undetected cracks (King Air) and improperly conducted AD-mandated inspections (Cessna Turbocharged Piston Twins) posing ongoing safety risks.
  • Component quality issues were observed, such as premature "weather checking" and failures in recently manufactured tire tubes for the Cessna 172R, and loose turbocharger oil lines on a Cirrus SR22.
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Beechcraft E90 King Air

Cracked Wing Spar Caps

The forward outboard, lower wing spar caps were found cracked. The cracks-on both left and righthand assemblies-radiated out from the fourth Huck rivet forward, passing through the wing attach hinge. This aircraft was inspected 15

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