2003-07-01: Lower spar caps

2003-07-01 Quality Aerospace, Inc. (Ayres Corporation formerly held Type Certificate (TC) No. A4SW): Amendment 39-13097; Docket No. 2001-CE-37-AD; Supersedes AD 2000-11-16, Amendment 39-11764. (a) What airplanes are affected by this AD? This AD affects the following airplane models and serial numbers that are certificated in any category and do not incorporate a P/N 22507 lower spar cap on both the left and right wings: Model Serial Nos. Group (1) S-2R 5000R through 5099R, except 5010R, 5031R, 5038R, 5047R, and 5085R 1 (2) S2R-G1 G1-101 through G1-106 1 (3) S2R-R1820 R1820-001 through R1820-035 1 (4) S2R-T15 T15-001 through T15-033 1 (5) S2R-T34 6000R through 6049R, T34-001 through T34-143, T34-145, T34-147 through T34-167, T34-171, T34-180, and T34-181. 1 (6) S2R-G10 G10-101 through G10-136, G10-138, G10-140, and G10-141 2 (7) S2R-G5 G5-101 through G5-105 2 (8) S2R-G6 G6-101 through G6-147 2 (9) S2RHG-T65 T65-002 through T65-018 2 (10) S2R-R1820 R1820-036 2 (11) S2R-T34 T34-144, T34-146, T34-168, T34-169, T34-172 through T34-179, and T34-189 through T34-232, and T34-234. 2 (12) S2R-T45 T45-001 through T45-014 2 (13) S2R-T65 T65-001 through T65-018 2 (14) 600 S2D All serial numbers beginning with 600-1311D 3 (15) S-2R 1380R and 1416R through 2592R 3 (16) S2R-R1340 R1340-001 through R1340-035 3 (17) S2R-R3S R3S-001 through R3S-011 3 (18) S2R-T11 T11-001 through T11-005 3 (19) S2R-G1 G1-107, G1-108, and G1-109 4 (20) S2R-G10 G10-137, G10-139, and G10-142 4 (21) S2R-T34 T34-236, T34-237, and T34-238 4 (22) S2R-G1 G1-110 through G1-115 5 (23) S2R-G10 G10-143 through G10-165 5 (24) S2R-G6 G6-148 through G6-155 5 (25) S2RHG-T34 T34HG-101 and T34HG-102 5 (26) S2R-T15 T15-034 through T15-040 5 (27) S2R-T34 T34-239 through T34-270 5 (28) S2R-T45 T45-015 5 (29) S2R 5010R, 5031R, 5038R, 5047R, and 5085R 6 Note 1: The serial numbers of the Model S2R-T15 airplanes could incorporate T15-xxx and T27-xxx. This AD applies to both of these serial number designations as they are both Model S2R-T15 airplanes. Note 2: The serial numbers of the Model S2R-T34 airplanes could incorporate T34-xxx, T36-xxx, T41-xxx, or T42-xxx. This AD applies to all of these serial number designations as they are all Model S2R-T34 airplanes. Note 3: Any Group 3 airplane that has been modified with a hopper of a capacity more than 410 gallons, a piston engine greater than 600 horsepower, or any gas turbine engine, makes the airplane a Group 1 airplane for the purposes of this AD. Inspect the airplane at the Group 1 compliance time specified in this AD. (b) Who must comply with this AD? Anyone who wishes to operate any of the airplanes identified in paragraph (a) of this AD must comply with this AD. (c) What problem does this AD address? The actions specified by this AD are intended to detect and correct fatigue cracking of the lower spar caps, which could result in the wing separating from the airplane with consequent loss of control of the airplane. (d) What actions must I accomplish to address this problem? To address this problem, you must accomplish the following: (1) Repetitively inspect, using magnetic particle, ultrasonic, or eddy current procedures, the \1/4\-inch and \5/16\-inch bolt hole areas on each lower spar cap for fatigue cracking. Reference paragraph (e)(3) and (e)(4) of this AD (including all subparagraphs) to obtain the initial and repetitive inspection compliance times. (i) The cracks may emanate from the bolt hole on the face of the spar cap or they may occur in the shaft of the hole. (ii) You must inspect both of these areas. (iii) If using the magnetic particle method for the inspection, perform the inspection using the "Inspection" portion of the "Accomplishment Instructions" and "Lower Splice Fitting Removal and Installation Instructions" in Ayres Service Bulletin No. SB-AG- 39, dated September 17, 1996. You must follow American Society for Testing Materials (ASTM) E 1444-01, using wet particles meeting the requirements of the Society for Automotive Engineers (SAE) AMS 3046. The inspection must be performed by or supervised by a Level 2 or Level 3 inspector certified for magnetic particle inspection method using the guidelines established by the American Society for Nondestructive Testing or MIL-STD-410. CAUTION: You must firmly support the wings during the inspection to prevent movement of the spar caps when the splice blocks are removed. This will allow easier realignment of the splice block holes and the holes in the spar cap for bolt insertion. (iv) If using ultrasonic or eddy current methods for the inspection, a procedure must be sent to the FAA Atlanta Aircraft Certification Office (ACO) for approval prior to performing the inspection. Send your proposed procedure to the FAA Atlanta Aircraft ACO, Attn: Cindy Lorenzen, One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, Georgia 30349. You are not required to remove the splice block for either the ultrasonic or eddy current inspections, unless corrosion is visible. (2) If any cracking is found during any inspection required by this AD, you must accomplish the following: (i) Repair or replace: (A) Use the cold work process to ream out small cracks as defined in Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996; or (B) Ream the 1/4-inch bolt holes to 5/16 inches diameter as defined in Part I of Ayres Custom Kit No. CK-AG-29, dated December 23, 1997; or (C) Install Kaplan Splice Blocks as defined in Quality Aerospace, Inc. Custom Kit No. CK-AG-30, dated December 6, 2001; or (D) Replace the affected spar cap in accordance with the maintenance manual. (ii) Submit a report of inspection findings to the Manager, Atlanta ACO, One Crown Center, 1895 Phoenix Boulevard, Suite 450, Atlanta, Georgia 30349; facsimile: (770) 703-6097. You must include: (A) The airplane serial number and engine model number; (B) The total number of flight hours on the lower spar cap that is cracked; (C) Time on the spar cap since last inspection, if applicable; (D) The procedure (magnetic particle, ultrasonic, or eddy current) used for the last inspection; (E) Indicate if cold working has been accomplished or modifications incorporated such as installation of big butterfly plates; (F) Indicate the time on the spar cap when the cold working or modifications were accomplished; and (G) Indicate which bolt hole is cracked and the length of the crack. Note 4: Information collection requirements contained in this regulation have been approved by the Office of Management and Budget (OMB) under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 et seq.) and have been assigned OMB Control Number 2120-0056. (e) What is the compliance time of this AD? The compliance times for each of theactions of this AD are as follows: (1) Any required repair or replacement: Prior to further flight after the inspection where the crack(s) was/were found. (2) Reporting requirement: (i) Submit the report within 10 days after finding any crack(s) during any inspection required by this AD. (ii) For airplanes where cracking was found during any inspection accomplished in accordance with AD 2000-11-16, which is superseded by this AD; or by AD 97-17-03, which was superseded AD 2000-11-16; or by AD 97-13-11, which was superseded by AD 97-17-03, submit the report within 10 days after May 20, 2003 (the effective date of this AD), unless already accomplished. (3) Initial inspection: Required unless already accomplished (compliance with AD 2000-11-16, or AD 97-17-03, or AD97-13-11) within 50 flight hours after May 20, 2003 (the effective date of this AD) or upon the accumulation of these hours time-in-service (TIS) on each lower spar cap, whichever occurs later:Airplane group Lower spar cap hours TIS (i) 1 2,000 (ii) 2 2,200 (iii) 3 6,400 (iv) 4 2,500 (v) 5 6,200 (vi) 6: For S/N 5010R: 5,530 For S/N 5038R: 5,900 For S/N 5031R: 6,400 For S/N 5047R: 6,400 For S/N 5085R: 6,290 (4) Repetitive inspections: The following table gives the required repetitive inspection intervals based on the work performed and the method of inspection utilized. Each time is hours TIS after the last inspection: Work previously performed Magnetic par- ticle hours TIS Ultrasonic hours TIS Eddy current hours TIS (i) One of the following where the airplane does not have butterfly plates, part number (P/N) 20211-09 and P/N 20211-11, installed per CK-AG-29, Part II (A) No cracks found previously on wing spar; or (B) Small cracks repaired through cold work (or done as an option if never cracked) accomplished per SB-AG-39; or (C) Small cracks repaired through 1/4-inch bolt hole reamed to 5/16inch diameter (or done as an option if never cracked) per CK-AG-29, Part I; or (D) Small cracks repaired through previous Alternative Methods of Compliance; or (E) Small cracks repaired by installation of Kaplan Splice Blocks, part number 22515-1-3 or 88-251 (or done as an option if never cracked) per CK-AG-30 and inspection of the six outboard bolt holes on both lower spars is required 500 550 700 (ii) One of the following where the airplane has butterfly plates, part number (P/N) 20211-09 and P/N 20211-11, installed per CK-AG-29, Part II (A) No cracks found previously on wing spar; or (B) Small cracks repaired through cold work (or done as an option if no cracks found) accomplished per SB-AG-39; or (C) Small cracks repaired through 1/4-inch bolt hole reamed to 5/16 inch diameter (or done as an option if no cracks found) per CK-AG-29, Part I; or (D) Small cracks repaired through previous Alternative Methods of Compliance; or (E) Small cracks repaired by installation of Kaplan Splice Blocks, part number 22515-1-3 or 88-251 (or done as an option if never cracked) per CK-AG-30 and inspection of the six outboard bolt holes on both lower spar caps is required (iii) Cracked wing spar found during previous inspection with wing spar replacement 900 950 1,250 For all inspection methods (magnetic particle, ultrasonic, or eddy current), time for initial and repetitive inspection intervals start over when wing spar is replaced. Note 5: Aircraft S/Ns T45-007DC and T45-010DC had modified splice block assemblies installed at Ayres (Ayres/Kaplan Assembly No. 88-251) and must still follow the repetitive inspection intervals listed here. Note 6: If a crack is found, the reaming associated with the cold work process may remove a crack if it is small enough. Some aircraft owners/operators were issued alternative methods of compliance with AD 97-17-03 to ream the \1/4\-inch bolt hole to \5/ 16\ inch diameter to remove small cracks. Ayres CK-AG-29, Part I, also provides procedures to ream the \1/4\-inch bolt hole to \5/16\ inch diameter. If you use either of these two methods to remove cracks and the airplane is reinspected immediately with no cracks found, you may continue to follow the repetitive inspection intervals listed above. Note 7: Group 4 and Group 5 airplanes had the butterfly plates installed at the factory and may follow the repetitive inspection interval listed in paragraph (e)(4)(ii). (f) Can I comply with this AD in any other way? (1) You may use an alternative method of compliance or adjust the compliance time if: (i) Your alternative method of compliance provides an equivalent level of safety; and (ii) The Manager, Atlanta ACO, approves your alternative. Submit your request through an FAA Principal Maintenance Inspector, who may add comments and then send it to the Manager, Atlanta ACO. (2) Alternative methods of compliance approved in accordancewith AD 2000-11-16, which is superseded by this AD, are approved as alternative methods of compliance with this AD. Note 8: This AD applies to each airplane identified in paragraph (a) of this AD, regardless of whether it has been modified, altered, or repaired in the area subject to the requirements of this AD. For airplanes that have been modified, altered, or repaired so that the performance of the requirements of this AD is affected, the owner/ operator must request approval for an alternative method of compliance in accordance with paragraph (f) of this AD. The request should include an assessment of the effect of the modification, alteration, or repair on the unsafe condition addressed by this AD; and, if you have not eliminated the unsafe condition, specific actions you propose to address it. (g) Where can I get information about any already-approved alternative methods of compliance? Contact Cindy Lorenzen, Aerospace Engineer, FAA, Aircraft Certification Office, One Crown Center, 1895 Phoenix Boulevard, suite 450, Atlanta, Georgia 30349; telephone: (770) 703-6078; facsimile: (770) 703-6097. (h) What if I need to fly the airplane to another location to comply with this AD? The FAA can issue a special flight permit under sections 21.197 and 21.199 of the Federal Aviation Regulations (14 CFR 21.197 and 21.199) to operate your airplane to a location where you can accomplish the requirements of this AD provided that: (1) the hopper is empty; (2) Vne is reduced to 126 miles per hour (109 knots) indicated airspeed (IAS); and (3) flight into known turbulence is prohibited. (i) Are any service bulletins incorporated into this AD by reference? (1) Actions required by this AD must be done in accordance with Ayres Service Bulletin No. SB-AG-39, dated September 17, 1996; Ayres Custom Kit No. CK-AG-29, dated December 23, 1997; and Quality Aerospace, Inc. Custom Kit No. CK-AG-30, dated December 6, 2001. (i) The Director of the Federal Register approved the incorporation by reference of Quality Aerospace, Inc. Custom Kit No. CK-AG-30, dated December 6, 2001, under 5 U.S.C. 552(a) and 1 CFR part 51. You may get copies from Quality Aerospace, Inc., P.O. Box 3050, Albany, Georgia 31706-3050; telephone: (229) 883-1440; facsimile: (229) 883-9790. (ii) The Director of the Federal Register previously approved the incorporation by reference of Ayres Service Bulletin No. SB-AG- 39, dated September 17, 1996; Ayres Custom Kit No. CK-AG-29, dated December 23, 1997, as of July 25, 2000 (65 FR 36055, June 7, 2000). (2) You may get copies from Quality Aerospace, Inc., P.O. Box 3050, Albany, Georgia 31706-3050; telephone: (229) 883-1440; facsimile: (229) 883-9790. You may view copies at the FAA, Central Region, Office of the Regional Counsel, 901 Locust, Room 506, Kansas City, Missouri, or at the Office of the Federal Register, 800 North Capitol Street, NW, suite 700, Washington, DC. (j) Does this AD action affect any existing AD actions? This amendment supersedes AD 2000-11-16, Amendment 39-11764. (k) When does this amendment become effective? This amendment becomes effective on May 20, 2003.