Incident Overview
An air taxi pilot, who also owned the company, was conducting a takeoff from his base airport in rural Alaska. On board were a newly hired pilot and four passengers. Approximately one mile from the airport, the pilot and passengers noticed smoke and an odor of smoke. The pilot immediately returned to the airport and landed.
Post-Landing Actions
After landing, at the pilot's request, the new hire pilot exited the aircraft, checked the engine oil dipstick for security, then reentered the cockpit. The pilot proceeded with another takeoff.
Second Takeoff and Emergency
Shortly after the second takeoff, smoke began to fill the cockpit, and flames became visible emanating from the engine cowling. The pilot made an emergency landing on a small island just off the airport.
Fire Suppression
The occupants of the airplane extinguished the fire using water and a small fire extinguisher.
Postaccident Inspection
A subsequent inspection found a loose exhaust manifold and fire damage in the area near the exposed exhaust ports. Nuts that secure the exhaust manifold to the engine were discovered at the bottom of the cowling. The aircraft had undergone maintenance about one month prior that required removal of the left manifold.