Accident Sequence
On April 23, 2018, at about 1150 eastern daylight time, a Bellanca 7GCBC (registration N8737V) was substantially damaged during an accident near Andover, New Jersey. The pilot, who was seriously injured, was operating the aircraft as a personal flight under Title 14 Code of Federal Regulations Part 91. The pilot had earlier conducted a preflight inspection, sumping fuel from various points, and during taxi smelled smoke. After inspecting the engine compartment with the airport manager and finding no bird's nest, he refueled with 13 gallons. An engine run-up and takeoff were normal, but at about 500 ft above ground level, the pilot noted decreasing rpm. He applied carburetor heat with no improvement, then landed uneventfully back at the airport. A walk-around inspection revealed no anomalies.
Previous Flight and Maintenance Attempts
After the first landing, the pilot and a mechanic searched for the cause. The mechanic found the intake cuff moderately deteriorated and incorrectly installed, and the No. 3 exhaust manifold had loose nuts. They replaced gaskets and hardware, but the mechanic did not observe the pilot's installation. The mechanic also found a kink in the main fuel supply line, which was made of unreinforced automotive hose, and replaced it. The pilot then conducted a full-throttle run-up and walk-around, noting no issues. Despite these repairs, the pilot took off again for the next flight.
Final Flight
During the second takeoff, after climbing to about 300 ft agl, the pilot again experienced a rapid decrease in rpm. He turned slightly right toward a field, but had to lower the nose to maintain flight, losing that landing option. He then turned left toward the departure airport, but the engine lost all power about one-third through the turn. The pilot pulled the nose up just before impact with water. The airplane sank in 44 ft of water and was recovered about 24 hours later. The pilot egressed and was rescued by first responders.
Post-Accident Examination
Examination of the airframe and engine revealed no evidence of any preaccident mechanical malfunction or failures that would have precluded normal operation. The airport manager observed the second takeoff and described the engine sputtering and stalling at about 200 ft, followed by a left turn and sharp descent, with the pilot leveling just before impact. The mechanic heard a similar power reduction pattern to the first flight. The aircraft's maintenance records showed an engine overhaul on May 1, 2015, and an annual inspection on May 4, 2017; no further records were provided.