Van'S Aircraft RV-10 accident near Beaver Dam, Wisconsin, July 22, 2022
On July 22, 2022 at about 9:47 pm local time, a 2021 Van'S Aircraft RV-10, an amateur-built aircraft,, registered N4400K, was substantially damaged in an accident during enroute near Beaver Dam, Wisconsin. It was a personal flight under general aviation rules (Part 91). 1 person had minor injuries; 2 others were unhurt. The weather was visual conditions (good weather).
The NTSB's probable cause their words, unchanged
The improperly secured spark plug boot that resulted in smoke in the cockpit and a subsequent off-airport landing.
Source: NTSB aviation accident database, copy made October 5, 2026. Docket and reports at the NTSB.
What the record shows
- Date
- July 22, 2022 · about 9:47 pm local time
- Place
- Beaver Dam, Wisconsin · map
- Type
- Accident
- Injuries
- 1 person had minor injuries; 2 others were unhurt.
- Weather
- visual conditions (good weather)
- Aircraft
- Van'S Aircraft RV-10 NO SERIES, built 2021, amateur-built
- Registration
- N4400K · no longer on the register · serial 42074
- Damage
- Substantial damage
- Flight
- Personal flight · general aviation rules (Part 91)
The NTSB's narrative final · quoted from the NTSB record
The pilot of the airplane stated that after departure he heard a “very loud pop” from the engine and then saw smoke enter the cockpit. After the smoke cleared, he decided to perform an off-airport landing even though the engine continued to operate. He stated that he did not check the engine gauges to evaluate any anomalies. The pilot reported that the engine was operating after he heard the “loud pop” noise. During the approach to the field, the pilot added engine power to avoid hitting power lines. The airplane impacted a soccer goal, a streetlight, and a portable toilet, which resulted in substantial damage to the fuselage and right wing. Postaccident examination of the engine found the spark plug wire boot for the No. 6 cylinder was not connected to the spark plug and was found resting on the exhaust pipe. The rubber boot likely sustained thermal damage when it contacted the exhaust pipe; there were no other mechanical anomalies that would have precluded normal operation. A review of the maintenance records showed that 79.7 hours had accumulated on the engine since the last inspection, which was a condition inspection. It possible that the spark plug wire boot was not secured during the last maintenance work performed. Based on the available records, investigators were not able to determine why the spark plug wire boot was unsecured.
The complete narrative as the NTSB published it. The NTSB's docket holds the report as a PDF and any photographs, statements and other documents from the investigation.
The factual record from the NTSB's investigation tables, in plain English
What happened, in order
- Powerplant sys/comp malf/fail during enroute defining event
- Fire/smoke (non-impact) during enroute
- Off-field or emergency landing during landing
- Collision during takeoff/land during landing
The NTSB's findings
- Aircraft › Aircraft power plant › Ignition system › Spark plugs/igniters › Damaged/degraded
- Aircraft › Aircraft power plant › Ignition system › Spark plugs/igniters › Incorrect service/maintenance
Pilot
- Certificate: private
- Ratings: single-engine land
- Flight time: 783 hours in all; 200 in this make and model; 28 in the last 90 days; 12 in the last 30 days; 783 as pilot in command
- Last flight review: September 22, 2021
- Medical certificate: Class 3 (with waivers/limitations)
- Seat: left
- Injury: no injuries
The aircraft
- Airframe total time: 212.5 hours
- Last inspection: annual inspection, March 22, 2022; 79.7 hours since
- Maximum gross weight: 2,700 lb
- Seats: 4
- Landing gear: fixed
- Engine: Lycoming Engines YIO-540-D4A5 (piston); 200 hours total
The flight
- Departed from: UNU Juneau WI at 9:38 pm
- Destination: OSH Oshkosh WI
- Flight plan: none
Weather at the time
- Light: daylight
- Wind: from 220° at 13 knots, gusting 20
- Visibility: 10 statute miles
- Sky: scat at 11,000 ft
- Temperature: 86°F (30°C), dew point 63°F (17°C)
- Altimeter: 29.92 inHg
- Observation at 4:35 pm from KUNU, 6 miles away
Weather report (METAR): KUNU 222135Z AUTO 22013G20KT 10SM SCT110 30/17 A2992 RMK AO2 T02950173
Injuries
| Fatal | Serious | Minor | None | |
|---|---|---|---|---|
| Flight crew | 1 | |||
| Passengers | 1 | 1 |
Documents from the investigation the NTSB's docket: the evidence folder behind the report
11 documents, released by the NTSB on February 7, 2024. View them here, or download them; the NTSB redacts some personal details before release, and this site shows the NTSB's own titles rather than its file names.
| # | Document | What it is | |
|---|---|---|---|
| 1 | Accident Photographs | PDF, 6 pages | View Download |
| 2 | Pilot/operator Aircraft Accident Report, NTSB Form 6120.1 | PDF, 9 pages | View Download |
| 3 | FAA Aviation Safety Inspector - Statement | PDF, 5 pages | View Download |
| 4 | Airplane Flight Logs and Maintenance Records | PDF, 6 pages | View Download |
| 5 | Pilot Logbook Excerpts | PDF, 1 page | View Download |
| 6 | ADS-B Data (Google Earth File) | map file | Download |
| 7 | ADS-B Data (Microsoft Excel File) | spreadsheet | Download |
| 8 | Electronic Flight Information System - Specialist's Factual Report | PDF, 12 pages | View Download |
| 9 | Electronic Flight Information System - Specialist's Factual - ATTACHMENT1 | data file | Download |
| 10 | Release of Aircraft Wreckage, NTSB Form 6120.15 | PDF, 1 page | View Download |
| 11 | NTSB Party Member Form - Lycoming Engines | PDF, 1 page | View Download |
The same docket at the NTSB · documents without a copy here are fetched from the NTSB when you open them.
Everything on this page comes from the NTSB's public records. The narrative, probable cause and findings are the NTSB's own words; the coded tables behind the report are written out in plain English, with pilots' ages, home towns and medical details left out. The documents and photographs are the NTSB's docket, shown as the NTSB released them. This site's own text never names anyone involved. A preliminary report can change; the final report usually follows one to two years later, and the page is refreshed when it does.
