Incident Details
The pilot reported that an unsafe gear door light was displayed shortly after departure. He recycled the landing gear, but the right main landing gear did not extend. He performed several normal and emergency gear extension attempts, all unsuccessful. He had several telephone patch conversations with the airplane manufacturer and flight safety personnel. Unable to lower the right main landing gear, he orbited to burn down fuel, declared an emergency, and conducted a gear-up landing.
Examination Findings
Examination of the right main landing gear revealed a fatigue fracture in the right inboard landing gear door forward hinge bracket. The door was wedged in the wheel well.