Casualties unknown

Fatigue Damage Identified on Wing Spar Following Positioning Flight (N403BK)

Hyannis, MA, US

On February 11, 2005, a Cessna 402C (registration N403BK) operated by Island Airlines was involved in an aviation accident near Hyannis, MA. Investigators recorded the probable cause as: Fatigue damage originating at the forward portion of the rivet hole on the spar cap at wing station 114. This summary draws on records from the U.S. National Transportation Safety Board (NTSB) historical archive; 1 related events involving the same aircraft type or operator are linked below.

Sourcesthe U.S. National Transportation Safety Board (NTSB) historical archivePrimary reportUpdated 2026-06-10Data APIEditorial standards

A pilot noticed aileron trim needed to maintain level flight during a positioning flight. Examination after landing revealed fatigue cracks on the left wing's forward spar cap, web doublers, and skin, with corrosion suggesting the cracks existed at the last inspection.

Incident

During a positioning flight, the pilot observed that the airplane required aileron trim to maintain level flight. The airplane subsequently landed without further incident.

Inspection Findings

A post-flight examination of the airplane revealed two missing rivets on the underside of the left wing, located between the heat shield and a factory-installed doubler. The lower forward spar cap was found cracked at wing station (WS) 114, at a rivet hole just outboard of the outboard engine beam. Both the forward and aft web doublers were split near the end of the inboard wing spar web at WS 112.5. Additionally, the skin was cracked from the front spar lower cap up to the first stringer location behind the front spar.

Examination Details

At the time of the incident, the airplane had accumulated approximately 20,510 total operational hours. It was subject to Federal Aviation Administration Airworthiness Directive (AD) 2000-23-01, which required inspections of the forward, aft, and auxiliary wing spars for cracks at intervals not exceeding 110 hours time-in-service.

The cracked portion of the forward spar, skin, and aft web doubler were removed for further examination. This examination revealed fatigue damage that originated at the forward portion of the rivet hole on the spar cap at WS 114. Blackening and corrosion were observed on the fracture surface, consistent with the fracture being present at the time of the airplane's most recent inspection, which had been conducted approximately one week earlier, at 12 operational hours before the incident flight.

Probable cause

Fatigue damage originating at the forward portion of the rivet hole on the spar cap at wing station 114.

Investigation report by the U.S. National Transportation Safety Board (NTSB) historical archive. Original record: https://carol.ntsb.gov/event/20050224X00232. This page is a structured re-presentation; facts and quotes are in the National Transportation Safety Board (NTSB), United States.