PA44-180; Improperly Repaired Ailerons
<h2>Piper: PA44-180; Improperly Repaired Ailerons; ATA 5751</h2>
<p><em>(The following combines seven defect reports on the same make and model aircraft. Each report is from the from the same repair station and written by its chief inspector.)</em></p>
<p>During power off, clean configuration stalls, the aircraft would suddenly break left andif not immediately stoppedcould lead to a spin. After re-rigging all flight controls <em>(and confirming aircraft alignment with laserequipment), </em>several test flights were performed, both by company pilots and a Piper Factory test pilot. It was determined we had FAT ailerons on our fleet of Seminoles. Piper has a history of aileron skin cracking. For <em>(our operation) </em>this recurring defect has just been on the R/H ailerons. Once the crack is past a certain point one either has to replace the effected skin OR replace the aileron. During skin replacement, if the pre-formed factory skin is spread aparteven a littlethe trailing edge takes on a fat condition. This leads to the aileron not having the proper profile and <em>(as result) </em>creates lift at that portion of the aileron, causing control problems. This may seem like a small problem, but it can have big consequences. Also, when replacing the skins, the mechanic must be aware of and maintain the 1.79 degree washout built into the factory aileron. Unfortunately, this information is not currently in the Piper Maintenance Manuals. At this point we have replaced all of our right ailerons with new Piper units and the aircraft now exhibit normal flight characteristics. <em>(Aileron P/N 86562025. More information may be forth coming on this topic from the local district office FAA inspector.)</em></p>
<p><strong>Part Total Time: 3,634.3 hours <em>(average of seven).</em></strong><strong> </strong></p>
<p><em>(The following combines seven defect reports on the same make and model aircraft. Each report is from the from the same repair station and written by its chief inspector.)</em></p>
<p>During power off, clean configuration stalls, the aircraft would suddenly break left andif not immediately stoppedcould lead to a spin. After re-rigging all flight controls <em>(and confirming aircraft alignment with laserequipment), </em>several test flights were performed, both by company pilots and a Piper Factory test pilot. It was determined we had FAT ailerons on our fleet of Seminoles. Piper has a history of aileron skin cracking. For <em>(our operation) </em>this recurring defect has just been on the R/H ailerons. Once the crack is past a certain point one either has to replace the effected skin OR replace the aileron. During skin replacement, if the pre-formed factory skin is spread aparteven a littlethe trailing edge takes on a fat condition. This leads to the aileron not having the proper profile and <em>(as result) </em>creates lift at that portion of the aileron, causing control problems. This may seem like a small problem, but it can have big consequences. Also, when replacing the skins, the mechanic must be aware of and maintain the 1.79 degree washout built into the factory aileron. Unfortunately, this information is not currently in the Piper Maintenance Manuals. At this point we have replaced all of our right ailerons with new Piper units and the aircraft now exhibit normal flight characteristics. <em>(Aileron P/N 86562025. More information may be forth coming on this topic from the local district office FAA inspector.)</em></p>
<p><strong>Part Total Time: 3,634.3 hours <em>(average of seven).</em></strong><strong> </strong></p>