History of Flight
On September 4, 2013, about 1835 eastern daylight time, a Cessna 188B, N59JK, operated by Hopkins Flying Service, was substantially damaged during landing roll after a flight control malfunction at a private airport in Woodrow, South Carolina. The commercial pilot received minor injuries. Visual meteorological conditions prevailed for the aerial application flight conducted under 14 CFR Part 137.
The pilot reported that while spraying a cotton field near Lydia, South Carolina, he completed a pass and pulled up to turn right. During the climb, he applied right rudder as usual, but the right rudder pedal assembly broke off and went up against the back of the hopper tank.
The pilot decided to return to the private airport where the airplane was based in Woodrow, as it was larger than other spray strips in the area. Upon arrival, he flew over the top and used his cell phone to alert personnel that he would be landing without rudder control.
The landing was uneventful, but during the landing roll, the airplane began to turn left. The pilot had no way to correct the left turn. The airplane exited the left side of the runway and entered a soybean field. The right main landing gear then collapsed, and the right wing impacted the ground.
Pilot Information
According to FAA and pilot records, the pilot held a commercial pilot certificate with a rating for airplane single-engine land. His most recent FAA second-class medical certificate was issued on January 30, 2013. He reported 2,249 total hours of flight experience, with 1,392 hours in the accident airplane make and model.
Aircraft Information
The accident aircraft was a single-seat, strut-braced, low-wing monoplane designed for aerial application. It was manufactured in 1973 and had a complex history of ownership and modifications. At the time of the accident, the airplane had accrued 5,393.2 total hours of operation.
Wreckage and Impact Information
Examination of the wreckage revealed substantial damage to the right wing and landing gear structure. The right rudder pedal arm and right rudder bar were constructed of steel tubing. The right rudder pedal arm had fractured just above its mounting location on the right rudder bar. Both the right rudder pedal arm and the right rudder bar exhibited significant corrosion. A plug of flexible material similar to silicone sealant was found in the top of the right rudder pedal arm and also in the left rudder pedal arm.
Tests and Research
Materials laboratory examination revealed that the outboard side of the right rudder pedal was affixed using a cotter pin and modified fender washer and bolt/nut assembly not specified in the service manual. The inboard side used a cotter pin and bronze bushing, also not specified. The silicone plugs had remnants of corrosion product adhered to them, indicating corrosion existed before the silicone was applied.
Internal examination of the right rudder pedal arm showed heavy rust scaling. Tube wall thickness at the fracture was significantly reduced, measuring 0.030 inch at the thickest and 0.013 inch at the thinnest, compared to full thickness of about 0.054 inch at the top.
Maintenance records contained no record of when the modifications (fender washer, bushing, silicone plugs) were made, nor was there a record of Supplemental Inspection Number 27-20-01 being accomplished.