Incident Overview
On December 1, 2015, at 1037 eastern standard time, a Piper PA-32-260, registration N5568J, was substantially damaged during a forced landing shortly after departing from Opa Locka Executive Airport in Miami, Florida. The private pilot and two passengers sustained serious injuries. Visual meteorological conditions prevailed, and a visual flight rules flight plan had been filed for the flight to South Bimini Airport in the Bahamas. The flight was conducted under 14 Code of Federal Regulations Part 91.
Pilot Report
According to the pilot, as the airplane climbed through about 800 feet, the front seat passenger asked if he smelled something. The pilot agreed and both then saw light smoke around the dash and windshield area. The pilot initiated a turn back toward the airport, and almost immediately, the engine experienced a total loss of power. The pilot advised the airport tower controller of the problem but, realizing the airplane could not reach the airport, performed a forced landing off-airport.
Accident Sequence
The Federal Aviation Administration (FAA) inspector reported that the airplane first touched down on top of a parked tractor trailer, bounced over a canal, and came to rest upside down on a berm.
Post-Accident Examination
The airplane was recovered to a storage facility and examined under NTSB oversight. Soot, char marks, and thermal damage were noted on the left side of the cowling, both on the engine compartment side and externally. The left (pilot) side wall of the muffler exhibited metal erosion and was fractured completely around the area where the combined cylinder exhaust pipe attached to the muffler. Additional fractures and bent metal consistent with impact damage were present, along with dark staining covering about 50% of the top of the muffler. Dark staining was also noted on the combined cylinder exhaust pipe, particularly near the muffler, and on the No. 2 cylinder intake riser. The valve covers on the left side of the engine showed thermal darkening on their lower portions. Engine fuel lines had thermal damage but were not compromised. The front of the carburetor was charred, and ignition wires on the left side were charred with sections of insulation missing. Engine crankshaft continuity and cylinder compression were confirmed.
The right side wall of the muffler was stained, and the metal was thin and rusted with small erosion holes.
Maintenance History
According to engine and airframe logbooks, the Lycoming O-540E4B5 engine underwent a major overhaul in December 2002 and was installed on the airframe on December 18, 2002, at 0 tachometer hours. On January 11, 2005, at 122.6 tachometer hours, exhaust gaskets were replaced with new hardware. The most recent annual/100-hour inspection was completed on June 17, 2015, at 468.8 tachometer hours. The same mechanic had performed the last three inspections, and no exhaust system anomalies were noted. The accident occurred at 476.0 tachometer hours.
Service Information
The Piper PA-32-260/300 Service Manual specifies that a thorough inspection of the entire exhaust system, including heat exchange shroud, muffler, muffler baffles, stack, and all exhaust connections, must be accomplished at each 100-hour inspection. The manual describes inspection methods and provides a figure showing typical muffler fatigue areas, including side walls.
FAA Advisory Circular (AC) 91-59A, "Inspection and Care of General Aviation Aircraft Exhaust Systems," emphasizes safety hazards of poorly maintained exhaust systems, points where failures occur, and recommends ongoing preventive maintenance. The AC notes potential failures can include leakage of exhaust gas into the cabin, partial or full engine power loss, or impingement heating/torching of surrounding structures.