Accident Overview
On August 1, 2008, at 1450 eastern daylight time, a Diamond DA-20-C1 airplane, registration N227RD, experienced a partial loss of engine power and conducted a forced landing in an open field near Peachtree City Airport-Falcon Field (FFC) in Atlanta, Georgia. The airplane sustained substantial damage. The certificated private pilot and a passenger received minor injuries. Visual meteorological conditions prevailed, and no flight plan was filed. The flight was operated by Falcon Aviation Academy as a local maintenance test flight under 14 CFR Part 91.
Flight and Maintenance Background
The airplane's rudder cables were scheduled for replacement per the manufacturer's maintenance program. To access the cables, the fuel tank was removed. After cable replacement and fuel tank installation, all required functional tests and leak checks were completed with no discrepancies. The operator's maintenance representative requested a test flight in the airport traffic pattern to verify rudder system function before returning the airplane to service.
The pilot conducted a preflight inspection and found no deficiencies. The fuel gauge reading matched a dip stick reading of half a tank. Startup, taxi, and pre-takeoff run-up were normal. After takeoff, the airplane climbed at 700 to 800 feet per minute with full throttle. During the downwind leg, the pilot reduced power to 1,500 rpm and extended the downwind by half a mile due to traffic. While turning base, the pilot advanced the throttle to add power but the engine did not respond; the tachometer indicated 800 rpm. Full power produced no increase in rpm. The pilot determined the airplane could not reach the runway and elected to force-land in an open field. During the landing roll, the airplane struck cut tree debris, separating the empennage and engine from the fuselage before stopping. The pilot and passenger exited unassisted.
Pilot and Aircraft Information
At the time of the accident, the pilot had 237 total flight hours, with 60 hours in the accident make and model. The airplane had accumulated 2,807 total hours. The IO-240-B Teledyne Continental Motor engine had 547 hours since major overhaul and 2,538 total service hours.
Wreckage Examination
A post-accident examination of the airframe and engine was conducted with oversight from the Federal Aviation Administration, the airframe manufacturer, the engine manufacturer, and the operator. No discrepancies were found in the flight control system that would have prevented normal operation. However, the examination revealed that a check valve in the engine mechanical fuel pump return hose line to the fuel tank was installed incorrectly; the arrow stamped on the valve indicating proper flow direction was reversed. The check valve had not been removed during the fuel tank removal and installation; only the hose itself was removed. The condition of the check valve was consistent with installation at the time of the airplane's assembly. The manufacturer did not require time-based replacement for the check valve. The airplane's maintenance manual for fuel tank removal and installation did not include a step to verify correct check valve orientation. The check valve was removed and retained for further examination.
Engine Testing
The engine was examined and test-run at Teledyne Continental Motors, Inc., with National Transportation Safety Board oversight. Two test runs were conducted: one with the check valve installed correctly and another with it installed backwards. Both tests showed minimal parameter deviations; the engine accelerated normally without hesitation or power interruption. No discrepancies were found that would have prevented the engine from producing power for normal flight operations.