Skin Game

Receiving inspection of a new Cessna leading edge skin (p/n 0523029-4) found it was drilled incorrectly. None of the nose ribs would line up with the rivet holes. The submitter wrote, "This (is) the second time we have received this same part. We have asked for this part not to be put back into Cessna stock since [it] is non-conforming. [It] came with an FAA Form 8130-3 Airworthiness Approval Tag."

Editorial Staff

Wednesday, March 21, 2007 at 12:00 AM ET

Verified

Key Takeaways:

New aircraft parts were received with significant manufacturing defects, such as an incorrectly drilled leading edge skin, even with an FAA airworthiness approval tag.
Critical components like Ercoupe landing gear bolts and Piper rudder bars failed due to wear and fatigue, prompting recommendations for time-based replacements.
Post-maintenance issues led to failures, including a magneto cam follower melting, and safety hazards, such as a starter cable chafing and causing an electrical fire.
Structural integrity concerns were identified with the discovery of a compression crack in a wooden wing spar during a required inspection.

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Cessna 172N

Nonconforming Leading Edge Skin

Receiving inspection of a new Cessna leading edge skin (p/n 0523029-4) found it was drilled incorrectly. None of the nose ribs would line up with the rivet holes. The submitter wrote, “This (is) the second time we have received this same part. We have asked for this part not to be put back into Cessna stock since [it] is non-conforming. [It] came with an FAA Form 8130-3 Airworthiness Approval Tag.”

Part Total Time: 0.00 hours.

Ercoupe A1

Sheared Landing Gear Bolts

A mechanic states, “These bolts are located at the top of the landing gear. Three