Piper PA-32-300 accident near Racine, Wisconsin, August 6, 2001
On August 6, 2001 at about 3:30 pm local time, a Piper PA-32-300, registered N5481T, was substantially damaged in an accident near Racine, Wisconsin. It was a personal flight under general aviation rules (Part 91). No one was hurt; 1 person was on board or involved. The weather was visual conditions (good weather).
The NTSB's probable cause their words, unchanged
The total loss of engine power during cruise flight due to the number 3 cylinder thru-studs fatigue fractures, and the thru-stud's low hardness as a result improper heat treatment of the thru-studs, and the unsuitable terrain encountered during the forced landing.
Source: NTSB aviation accident database, copy made October 5, 2026. Docket and reports at the NTSB.
What the record shows
- Date
- August 6, 2001 · about 3:30 pm local time
- Place
- Racine, Wisconsin · map
- Type
- Accident
- Injuries
- No one was hurt; 1 person was on board or involved.
- Weather
- visual conditions (good weather)
- Aircraft
- Piper PA-32-300 · all PA-32-300s on the register
- Registration
- N5481T · registry record · serial 32-7240107
- Damage
- Substantial damage
- Flight
- Personal flight · general aviation rules (Part 91)
The NTSB's narrative final · quoted from the NTSB record
The airplane sustained substantial damage during a forced landing to a soybean field after a complete loss of engine power. The pilot reported he was flying in cruise flight at 2,800 feet mean sea level. The airplane was operating normally with no abnormal engine indications. He reported that he heard a "loud bang" and experienced a complete loss of engine power. He attempted to restart the engine but with no success. He declared an emergency and executed a forced landing to a soybean field. The on-site inspection of the airplane revealed that the number 3 cylinder and connecting rod had separated from the engine. The examination of the engine revealed that all eight hold down studs on the number 3 cylinder deck were broken and exhibited fatigue fractures. The metallurgical examination of the upper front and lower front 1/2 inch thru-studs revealed they had fractured through approximately 95% and 90%, respectively, of their cross-sections by fatigue as characterized by the smooth transgranular topography and beach marks. The hardness of the studs was below the engineering drawing requirements. The examination of the thru-studs indicated that the studs were not properly heat-treated. The 3/8 inch cylinder stud fractures were secondary to the anchored thru-stud fatigue fractures. The hardness of the other thru-studs in the crankcase was also below the requirements outlined in engineering drawings. The maintenance records revealed that the engine had been overhauled at an engine overhaul facility on February 11, 1999. It had accumulated about 532 hours of flight time since the last major overhaul. The engine overhaul facility did not, and was not required by the Federal Aviation Administration regulations or the engine manufacturer's overhaul manual, to test the engine thru-studs for hardness during the engine overhaul.
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
Pilot
- Certificate: private
- Ratings: multi-engine land; single-engine land; single-engine sea; instrument: airplane; rotorcraft: glider
- Flight time: 1,110 hours in all; 259 in this make and model; 88 in the last 90 days; 33 in the last 30 days; 950 as pilot in command
- Last flight review: October 4, 1999
- Medical certificate: Class 3 (valid medical--w/ waivers/lim.)
- Seat: left
- Injury: no injuries
The aircraft
- Airframe total time: 5,500 hours
- Last inspection: annual inspection, December 12, 2000; 104 hours since
- Maximum gross weight: 3,400 lb
- Seats: 6
- Landing gear: fixed
- Engine: Lycoming IO-540-K1A5 (piston); 0 hours total
The flight
- Departed from: CGX Meigs Airport IL at 3:00 pm
- Destination: RAC Racine WI
- Flight plan: none
Weather at the time
- Light: daylight
- Wind: from 250° at 8 knots
- Visibility: 10 statute miles
- Sky: broken clouds at 25,000 ft; clear
- Temperature: 82°F (28°C), dew point 68°F (20°C)
- Altimeter: 30.19 inHg
- Observation at 2:56 pm from ORD, 38 miles away
Injuries
| Fatal | Serious | Minor | None | |
|---|---|---|---|---|
| Crew | 1 |
Documents from the investigation the NTSB's docket: the evidence folder behind the report
The docket, the folder of records gathered during an investigation (maintenance records, photographs, witness statements, examinations), has not been read from the NTSB for this case yet; the list appears here once it has. Open the docket at the NTSB.
Other NTSB records under N5481T the same tail number, which may have belonged to a different aircraft at the time
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.