On December 13, 2020, about 1045 eastern standard time, a Flight Design CTSW, N138CT, was substantially damaged when it was involved in an accident near Marion, North Carolina. The airline transport pilot and one passenger sustained minor injuries. The airplane was operated as a Title 14 Code of Federal Regulations Part 91 personal flight.

The pilot reported that all preflight operations were routine for the cross-country flight to Frankfort, Kentucky. Shortly after liftoff at an airspeed of about 46 knots, the airplane suddenly yawed to the right and came back down on the runway. The pilot elected to reject the takeoff, but the airplane continued to veer to the right. The airplane then departed the runway and entered an area of soft terrain. The nosewheel collapsed, and the airplane nosed over.

The pilot also reported that the takeoff gross weight was 1,310 pounds, which was 10 pounds below maximum gross weight for the airplane. He also reported that “something failed in the rudder.”

Postaccident examination of the airplane found that the nose gear had collapsed and was crushed into the lower fuselage. The vertical stabilizer and rudder were structurally damaged. Flight control continuity was established from the rudder to the cockpit rudder pedals. The pedals were jammed and would not move. Further examination revealed that the collapsed nose gear bent the rod between the rudder pedal assembly and the nose gear steering linkage. Otherwise, the rudder was free and clear with full travel available. Flight control continuity was also confirmed from the elevator and ailerons to the cockpit controls.