Piper PA-32R-300 accident near Valley Springs, California, May 28, 1999
On May 28, 1999 at about 11:23 pm local time, a Piper PA-32R-300, registered N38908, was substantially damaged in an accident near Valley Springs, California. It was a business 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 fatigue failure and separation of the No. 6 connecting rod end cap, which led to a catastrophic failure of the engine. The fatigue crack initiation was due to galling on the rod end cap, which was most likely caused by an undetermined factory manufacturing process error during the engine rebuild.
Source: NTSB aviation accident database, copy made October 5, 2026. Docket and reports at the NTSB.
What the record shows
- Date
- May 28, 1999 · about 11:23 pm local time
- Place
- Valley Springs, California · map
- Type
- Accident
- Injuries
- No one was hurt; 1 person was on board or involved.
- Weather
- visual conditions (good weather)
- Aircraft
- Piper PA-32R-300 · all PA-32R-300s on the register
- Registration
- N38908 · registry record · serial 32R-7780487
- Damage
- Substantial damage
- Flight
- Business flight · general aviation rules (Part 91)
The NTSB's narrative final · quoted from the NTSB record
The airplane had a catastrophic engine failure while the pilot was in cruise flight at 4,500 feet. The pilot declared an emergency and began to perform the emergency checklist. The pilot located a flat field and struck a barbed wire fence during the landing roll, which damaged the wings and collapsed the nose gear. The engine was sent back to the Textron Lycoming factory for materials examination. The No. 6 connecting rod initially fractured through the cap with the fracture most likely initiating from an area of galling on the inner diameter of the cap. The fracture was propagated by a fatigue mechanism until it failed with catastrophic overload. Following the metallurgical examination on the No. 6 connecting rod and associated components, additional disassembly of the engine was accomplished that did not conform to investigative protocols. No measurements were taken of the case through bolt torque or the remaining rod end cap bolt torque. No determination was made whether the bearing inserts were of the correct size or assembled properly in engine build-up. Review of the engine maintenance records disclosed that it was remanufactured by the Lycoming factory in 1991, and had operated 869 hours since rebuild and installation in the airframe. No removal and replacement of cylinders was noted in the records.
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: commercial pilot
- Ratings: multi-engine land; single-engine land; single-engine sea; instrument: airplane
- Flight time: 2,525 hours in all; 1,800 in this make and model; 30 in the last 90 days; 7 in the last 30 days; 2,165 as pilot in command
- Medical certificate: Class 3 (valid medical--w/ waivers/lim.)
- Seat: left
The aircraft
- Airframe total time: 2,857 hours
- Last inspection: annual inspection, October 16, 1998; 75 hours since
- Maximum gross weight: 3,600 lb
- Seats: 6
- Landing gear: retractable
- Engine: Lycoming IO-540-K1G5D (piston); 0 hours total
The flight
- Departed from: MER Atwater CA at 11:00 pm
- Destination: 061 Cameron Park CA
- Flight plan: none
- Runway 0
Weather at the time
- Light: daylight
- Wind: from 270° at 17 knots
- Visibility: 10 statute miles
- Sky: clear
- Temperature: 81°F (27°C), dew point 36°F (2°C)
- Altimeter: 29.00 inHg
- Observation at 10:56 pm from SCK
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 N38908 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.