Amateur-built Edge 540-T accident near King City, California, November 11, 2003
On November 11, 2003 at about 8:20 pm local time, a amateur-built Edge 540-T, registered N540RC, was substantially damaged in an accident near King City, California (Mesa Del Rey Airport). It was an instructional flight under general aviation rules (Part 91). 2 people were seriously injured. The weather was visual conditions (good weather).
The NTSB's probable cause their words, unchanged
The after market manufacturer's improper application of a crankshaft , which exceeded the original manufacturer's intended use. A factor in the accident was the oil covering the windscreen, which restricted the pilot's ability to see.
Source: NTSB aviation accident database, copy made October 5, 2026. Docket and reports at the NTSB.
What the record shows
- Date
- November 11, 2003 · about 8:20 pm local time
- Place
- King City, California · Mesa Del Rey Airport · map
- Type
- Accident
- Injuries
- 2 people were seriously injured.
- Weather
- visual conditions (good weather)
- Aircraft
- Amateur-built Edge 540-T
- Registration
- N540RC · registry record · serial 2014
- Damage
- Substantial damage
- Flight
- Instructional flight · general aviation rules (Part 91)
The NTSB's narrative final · quoted from the NTSB record
The airplane lost engine power and subsequently overran the runway and impacted terrain while making an emergency landing at an airport. The pilot reported that about 5 minutes after takeoff he noticed a loss of oil pressure, followed by a loss of power. He decided to return to the departure airport, and while en route back the windscreen became obscured by engine oil. During the landing the pilot landed long and was unable to stop the airplane before it departed the runway environment. The airplane came to rest north of the departure end of runway 29 in a ditch. During the engine examination, the crankshaft was found cracked completely through diagonally across the counterweight hanging blade cheek located between connecting rod journal numbers five and six. Textron Lycoming was contacted regarding the crankshaft serial number and applicability to the Lycoming mandatory service bulletins (552 and 553) and FAA airworthiness directive (AD2002-19-03) relating to crankshaft manufacturing defects causing catastrophic in-service crankshaft failures. They said the crankshaft by serial number was a "small journal six" and therefore was not affected by the recall or inspections required by both the service bulletins or airworthiness directive. Lycoming service bulletins 552, 553, and airworthiness directive 2002-19-03 relate specifically to engines rated at 300 horsepower (hp) and above. The "small journal six" crankshaft is not a 300 hp crankshaft. It is typically utilized in engines producing no more than 260 hp. Textron Lycoming originally manufactured this crankshaft for installation into an AEIO-540-D4A5 model engine rated at 260 hp and 2,700 rpm. Therefore, neither the mandatory service bulletin nor the airworthiness directive were applicable. This engine was modified by a engine overhaul shop for installation in experimental airplanes and carried a data plate naming the shop as the manufacturer and labeling the engine as a AEIO-540-EXP. The engine closely resembles a Lycoming AEIO-540-L1B5 model rated at 300 hp and 2,700 rpm, but with other modifications proprietary to the overhaul shop that increased its horsepower rating to 340 hp.
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: airline transport pilot
- Ratings: multi-engine land; single-engine land; single-engine sea; instrument: airplane
- Flight time: 2,900 hours in all; 105 in this make and model; 36 in the last 90 days; 23 in the last 30 days; 2,400 as pilot in command
- Last flight review: May 1, 2003
- Medical certificate: Class 2 (valid medical--w/ waivers/lim.)
- Seat: rear
- Injury: minor injuries
Flight instructor
- Certificate: flight instructor, commercial pilot
- Ratings: multi-engine land; single-engine land; instructor: airplane single-engine; instructor: glider; instrument: airplane; rotorcraft: glider
- Medical certificate: Class 2 (valid medical--no waivers/lim.)
- Seat: frt
- Injury: serious injuries
The aircraft
- Airframe total time: 100 hours
- Last inspection: annual inspection, February 19, 2003; 55 hours since
- Maximum gross weight: 1,950 lb
- Seats: 2
- Landing gear: fixed
- Engine: Lycon AEI0-540-EXP (piston); 0 hours total
The flight
- Departed from: KIC King City CA at 8:15 pm
- Destination: KIC King City CA
- Flight plan: none
- Runway 29, 4,485 ft by 1,367 ft
- A second pilot was aboard
Weather at the time
- Light: daylight
- Visibility: 10 statute miles
- Sky: clear
- Temperature: 64°F (18°C), dew point 43°F (6°C)
- Altimeter: 30.14 inHg
- Observation at 8:20 pm from SNS, 35 miles away
Injuries
| Fatal | Serious | Minor | None | |
|---|---|---|---|---|
| Crew | 2 |
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.
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.