Accident Details
On February 11, 2009, at 1642 eastern standard time, a Piper PA-28-180, registration N55854, operated by KS Air Corporation as a 14 CFR Part 91 personal flight, lost total engine power during the initial climb from Sky Manor Airport in Pittstown, New Jersey. The airplane collided with trees and the ground, sustaining structural damage during the forced landing in a residential area. Visual meteorological conditions prevailed and no flight plan was filed. The flight originated at 1640. The certificated commercial pilot suffered serious injuries. The pilot-rated passenger received minor injuries.
Pilot and Passenger Statements
The pilot-rated passenger reported that no anomalies were noted during the preflight inspection or engine run-up. The departure was made from runway 25, with the pilot-rated passenger flying from the left front seat and the electric boost pump on. During the initial takeoff climb, the fuel pressure gauge indicated zero. The engine sputtered and quit. The pilot-rated passenger selected a forced landing area. The engine then restarted, and he began a shallow turn back to the airport. The engine quit again, and the airplane collided with trees and the ground. A postcrash fire occurred in the engine compartment, which was extinguished by a resident.
Aircraft and Engine Examination
Review of the aircraft logbooks showed the airplane was equipped with a Lycoming O-360-A4A engine. The engine had been field overhauled at tachometer time 5,502 hours on May 5, 2004, and placed in preserved storage until sold. The last annual inspection was completed on January 9, 2009, at 5,502 tachometer hours. The tachometer at the crash site indicated 5,506.79 hours, meaning the airplane had flown 4.79 hours since the last overhaul and annual inspection.
Examination by an FAA inspector revealed that the left wing had separated and the empennage sustained structural damage. Evidence of a small fire was observed near the air box and upper right rear section of the engine, near the magneto and harness. Airframe and flight control examination showed no precrash mechanical failure or malfunction.
The engine assembly was compressed against the lower firewall. The structural mounts were bent downward and the exhaust system partially crushed. Internal top end components examined with a borescope showed no preimpact anomalies. Spark plugs exhibited clean, light tan combustion deposits. The crankshaft was rotated by hand, establishing continuity of the crankshaft, camshaft, valve train, and accessory drives. Compression was present on all cylinders.
Fuel System Findings
Examination of the lubrication, induction, carburetor, ignition, magnetos, harness leads, and spark plugs revealed no anomalies. Fuel was present in all fuel lines and components forward of the gascolator on the firewall. During removal of the fuel system hoses to the carburetor, a loose fuel hose B-nut was discovered. No impact or fire damage was noted in that area. The loose B-nut was found to be one-half turn counterclockwise from the torqued position. It was located at the fitting from the fuel line that runs from the engine-driven fuel pump to the carburetor. All other fuel hose connections in the engine compartment were found tight and secure.
According to Lycoming Torque Value Recommendations (SSP1776), the required torque for a -6, 3/8 size flexible hose fitting is 35 in-lbs. A follow-up fuel line leak test was conducted on another Piper PA-28-181 on February 23, 2009. With the fuel supply selector and electric boost pump on, the fuel pressure gauge indicated 4.5 PSI. When the fuel line B-nut at the exit side of the engine-driven fuel pump was loosened, the fuel pressure dropped to 3 PSI for 5 seconds, and fuel was observed leaking from the loosened B-nut.