What happened
On the day of the accident, the pilot departed Kissimimmee Gateway Airport in Kissimmee, Florida, bound for Sandusky, Ohio, with a planned refueling stop in Wilkesboro, North Carolina. Before the initial departure at 0830, witnesses stated the pilot topped off the fuel tanks. During the first leg of the flight, the pilot contacted Jacksonville Center to report a vacuum pump malfunction and elected to return to Kissimmee.
The aircraft landed at Kissimmee at 0945. A mechanic subsequently removed and replaced the vacuum pump, after which the pilot departed again at 1230 to continue the original trip. There was no record of additional fuel being added to the Piper PA-24-250 following the return to the airport. The flight continued at 9,500 feet until 1555, when the pilot issued a distress call stating the aircraft was descending due to fuel exhaustion.
The total flight time for the day was 4 hours and 40 minutes, consisting of a 1 hour and 15 minute first leg and a 3 hour and 25 minute second leg. Based on the engine's power settings, the estimated fuel consumption was approximately 14.0 gallons per hour, while the aircraft's total usable fuel capacity is 56 gallons.
Findings
The pilot had topped off the fuel tanks prior to the first departure of the day, but no further fueling occurred after the return to Kissimmee for repairs. The flight duration exceeded the available fuel supply.