Accident Overview
On July 23, 2017, at approximately 1247 Pacific daylight time, a Piper PA-28R-180, registration N4594J, was substantially damaged during takeoff from runway 31R at Reid-Hillview Airport (RHV) in San Jose, California. The commercial pilot, who was the sole occupant, was not injured. The airplane was registered to Foluain Fabhcun LLC of Aptos, California, and operated by the pilot under 14 CFR Part 91 as a personal flight. Visual meteorological conditions prevailed, and no flight plan was filed for the cross-country flight, which was destined for Marina, California.
Flight Events
The pilot reported that the airplane had recently undergone extensive maintenance, including installation of avionics upgrades and right-seat brake pedals. The accident flight was the first since the maintenance was completed. During takeoff on runway 31R, as the airplane became airborne at about 80 miles per hour, it immediately entered an uncommanded roll to the left. The pilot attempted to correct the roll but was unable to, and subsequently reduced engine power. The airplane impacted the ground and came to rest upright on runway 31L.
Aircraft Examination
A Federal Aviation Administration inspector noted structural damage to the fuselage and left wing. The National Transportation Safety Board investigator-in-charge examined the aileron control system and found that when the control yoke was rotated for right aileron input, the left aileron moved upward and the right aileron moved downward—the opposite of the correct response. The aileron cables remained attached to the "T" bar aileron control chains, but the right aileron control cable was attached to the left-side chain, and the left aileron control cable was attached to the right-side chain. The cables crossed underneath the flap handle and center console area.
Mechanic Statements
During a telephone conversation, one of two mechanics who worked on the airplane reported performing an oil change and other work while the other mechanic installed a second set of rudder pedals with brake controls on the right side. This mechanic checked flight control cable tension and visually observed aileron movement while moving the yoke but did not notice the cables were crossed. He stated that all work was performed per the Piper Aircraft Maintenance Manual.
The second mechanic reported that he disconnected the aileron cables to facilitate installation of the rudder pedals and brake assemblies and later reattached them. He stated that he did not observe the ailerons while the other mechanic checked control deflections.
Pilot Actions
The pilot reported that before the flight, he performed a walk-around inspection and moved the ailerons but did not verify the direction of yoke movement. Prior to takeoff, he checked all flight control movements but did not verify the aileron direction relative to yoke input, as his primary focus was on the rudder and brakes, which had been recently worked on.
Investigation Findings
The investigation determined that the aileron control cables had been incorrectly connected, with the left and right cables reversed, leading to reversed aileron response. This condition was not detected during preflight inspections or maintenance checks.