Pilot Disregarded Smoke Warning, Forced Landing After Engine Failure (N5820H)

Accident Overview

During the takeoff roll, the pilot was advised by air traffic control that the aircraft was trailing smoke. The pilot disregarded the report, having observed smoke on previous occasions and considering it a normal condition. He continued the takeoff. Shortly thereafter, the aircraft experienced a thrust loss of the right engine. The pilot attempted to return to the airport but was unsuccessful. Evidence indicated single-engine performance degradation due to a 9.4% over-gross condition and the pilot's failure to raise the landing gear and feather the right propeller. The pilot executed a forced landing into a vacant lot.

Investigation Findings

Investigation revealed that the thrust loss was a result of the failure, due to chaffing, of the right unfeathering accumulator hose. The hose had been misrouted during engine installation. The original smoke observed by the pilot was due to cracks in the right exhaust system. These cracks originated from previous weld repairs performed during engine installation. Neither the hose misrouting nor the exhaust system cracks had been identified by the operator's maintenance personnel.