Accident Overview
On July 20, 2011, at about 1327 eastern daylight time, a Beech C35 (registration N1883D) experienced a total loss of engine power after takeoff from Medina Municipal Airport (1G5), Medina, Ohio. The certificated flight instructor took control and attempted to return to the airport, then executed a forced landing to a field approximately 400 feet from runway 27. The CFI and commercial pilot were uninjured. The airplane sustained substantial damage. The airplane was operated by Flight Services of Medina under Part 91 instructional flight. Visual meteorological conditions prevailed.
Flight Sequence
The CFI reported that after practicing maneuvers for 0.5 to 0.7 hours, they returned to 1G5 for takeoff and landing practice. During the first practice takeoff, the engine experienced a total loss of power about 200 feet above ground level. The CFI noted limited time for troubleshooting and landed on a small grass area beyond the departure end of runway 27 about 5-7 seconds later. The airplane struck several small trees.
Engine Examination
The engine, a Teledyne Continental E-185-8 (serial number 26742-D-1-8-R), underwent a test run under FAA supervision. Initial cold compression readings varied: cylinder 1 - 60/80, cylinder 3 - 10/80, cylinder 5 - 34/80, cylinder 2 - 52/80, cylinder 4 - 58/80, cylinder 6 - 12/80. The engine would not start after four attempts. The engine-driven fuel pump was found leaking at a seam. After bypassing the pump, the engine started and operated from idle to 2,600 rpm. Subsequent compression readings were: cylinder 1 - 70/80, cylinder 3 - 50/80, cylinder 5 - 64/80, cylinder 2 - 50/80, cylinder 4 - 64/80, cylinder 6 - 70/80.
Fuel Pump Testing
The leaking pump was a Thompson Products, Inc. TF 1900 (serial number TF48290W) with a sticker reading "JAN 55A". Bench testing showed intermittent leakage from a vent hole and continuous leakage from the nose seal. At 3,000 rpm, pressure was 8 psi, flow rate 130 lb/hr; at 4,500 rpm, pressure 9 psi, flow rate 0 lb/hr; at 4,000 rpm, pressure 9 psi, flow rate 0 lb/hr; at 3,500 rpm, pressure 9 psi, flow rate 30 lb/hr. When returned to 3,000 rpm, pressure oscillated between 7-9 psi and 15-17 psi, and the vent hole leaked. At 3,500 rpm again, pressure was 8 psi, flow rate 150 lb/hr, with no leak. Disassembly revealed a diaphragm without holes but through which test fluid could leak; it had an annotated "1956".
Maintenance Records
The operator's mechanic reported no serviceable tags for the pump. The engine had been overhauled at a maintenance facility that went bankrupt, and the engine was obtained during that bankruptcy. According to Teledyne Continental Service Information Letter SIL98-9A, engine-mounted components require overhaul at the same intervals as the engine, and E185 series engines are to be overhauled after 1,500 hours or 12 years, whichever occurs first. An engine logbook entry dated October 25, 1999, recorded an overhaul by Clydesdale, Inc. at a tachometer time of 84.0 hours. A June 14, 2010 entry indicated the fuel pump was repaired and inspected using a new gasket (part number 653487). The last annual inspection was August 31, 2010, at a tachometer time of 99.0 hours and aircraft total time of 4,598.11 hours. An entry dated February 14, 2011, at tachometer time 102.6 hours and engine total time 4,601.71 hours, showed time since overhaul as 22.2 hours.