Accident Details
On February 20, 2016, at about 1900 eastern standard time, a privately owned Liberty Aerospace XL-2, registration N568XL, experienced a runway excursion during takeoff at Orlando International Airport (MCO), Orlando, Florida. The commercial pilot and one passenger were not injured. The airplane, operating under 14 CFR Part 91 as a personal flight, was substantially damaged. Visual meteorological conditions prevailed, and no flight plan was filed for the flight destined for Spruce Creek Airport, Daytona Beach, Florida.
Pilot Narrative
The pilot reported landing uneventfully at MCO, taxiing to a fixed base operator, and securing the airplane. No discrepancies were noted with the toe brakes. After meeting his wife, he checked oil and fuel, started the engine, performed a brake check, and found no issues. He received taxi clearance to runway 18R and was then instructed to cross it for departure from runway 18L. After crossing, he felt a "softness" in the brakes but stopped. He and his wife conducted a brake test with no discrepancies.
Cleared for takeoff with traffic on a four-mile final, the pilot perceived a need for immediate departure. He added power and entered the runway at an angle for a rolling takeoff. With a slight crosswind from the right, the right brake failed, causing the airplane to veer left. Concerned about rollover or collision with runway signage, he stopped braking and added full power, clearing runway lights and signs. He aborted the takeoff and landed in grass, where the airplane contacted a ridge, collapsing all landing gear. He noted that flying at a commercial airport created pressure to expedite departure and that lack of maintenance availability on Saturday night influenced his decision to continue.
Brake Examination and Testing
After the accident, FAA inspection found no brake leakage. The right brake lining showed deterioration, corrosion, and discoloration of the disk compared to the left. During recovery, the brake line from the right caliper was disconnected, and fluid leaked from the line. No determination of fluid level or right brake functionality was made before line removal.
At a secure location, FAA inspection revealed minimal fluid in the brake reservoir and no fluid in the plastic tubing. The left caliper was free in sliding pins; the right caliper exhibited excessive sliding motion. Examination at the manufacturer's facility found both brakes partially disassembled. Left brake linings were in good condition; right brake linings showed corrosion, a crack, and edge crumbling. Bench testing showed the left brake met requirements; the right brake leaked past the piston at 30 psi (9.4 mL) but none at 600 psi. Disassembly revealed the right brake o-ring had a recessed area, indentation, scuff, and square shape, while the left was intact. After o-ring replacement, no leakage occurred. All dimensions met drawing requirements; lining dimensions exceeded minimums.
Maintenance History
The last annual inspection was completed on February 1, 2016, at 1,141.0 hours. Brakes were bled and serviced with MIL-5606 fluid. The mechanic stated he did not disconnect brake lines during the inspection. The owner reported being present and that brakes were tested with no discrepancies. Since the inspection, there were no brake issues except two previous right brake problems in 2013 attributed to incorrect o-ring installation.