Accident Overview
During the takeoff initial climb following a 3,000-foot ground roll, the pilot radioed, "Can't make it," and stated that he was returning to land. The airplane subsequently impacted the runway 6,300 feet from the start of the takeoff roll and was consumed by fire.
Background
The pilot was hired to ferry the airplane on an FAA-issued Special Flight Permit from Japan to Illinois. He held an FAA airframe and power plant technician certificate with inspection authority and was responsible for supplying and installing the fuel tank system necessary for the long-range trans-Pacific flight. While en route to Honolulu, the pilot diverted to Johnston Atoll due to a fuel flow problem from the ferry tanks to the aircraft fuel system. The pilot discussed the problem with the aircraft owner, and the routing of the ferry fuel tank hoses and potential interference by airplane structure and landing gear was identified as a possible problem area.
Fuel System and Modifications
After an 18-day delay at Johnston Atoll, the airplane was fueled with 50 gallons of 100LL aviation fuel sent by barge and 50 gallons of automotive fuel provided by the military. The airplane was then flown to Honolulu, where the pilot locally purchased and installed an additional 45-gallon fuel tank. Subsequently, the aircraft proceeded to Hilo. The departure from Hilo was for the estimated 2,023-mile leg to Oakland, California.
Aircraft Condition
The airplane was operating in an over-gross weight condition, which was within the authorized ferry flight weight limitation; however, the center of gravity (CG) was in excess of 2 inches aft of the aft limit. This CG variance was not authorized in the ferry permit.
Post-Impact Examination
The left engine was removed and successfully run, meeting all Continental test parameters. Disassembly of the left propeller disclosed marks consistent with operation at, or very near, the low pitch stop at the time of impact, indicating something less than full power. Automotive-type rubber hoses were found routed and draped from the ferry fuel tanks to the main gear wheel wells and through the airplane center section. An auxiliary tank hose was found draped through the left landing gear retract brace. The hose showed evidence of being compressed by interference with the airplane structure and the gear retract braces. No vapor return line to the left tank was found.