Accident Summary
On April 12, 2021, at about 1920 eastern daylight time, a Piper PA-28-140 airplane, registration N7242F, was substantially damaged during an accident in Weyers Cave, Virginia. The pilot sustained serious injuries, and the passenger received minor injuries. The flight was conducted under Title 14 Code of Federal Regulations Part 91 as a personal flight.
Pilot and Flight Details
The pilot reported planning a touch-and-go landing at Shenandoah Valley Regional Airport (SHD) followed by maneuvers until dark. He performed a normal preflight inspection and filled both fuel tanks. The flight was uneventful until he entered the traffic pattern for runway 23. On final approach, he opted for two notches of flaps due to an 8-knot crosswind. At about 100 feet above the runway and 90 mph, he decided to go around because the approach felt unstable. He applied full power, but the airplane did not gain altitude and began banking hard left. At about 50 feet, left of the runway, he applied right aileron and right rudder but had no further memory of the event.
Aircraft Examination
The engine remained attached, and the propeller was slightly bent at the crankshaft flange. Except for the alternator, accessories and base engine appeared undamaged. Cylinders No. 1 and 3 had chrome barrel markings; No. 2 and 4 had nitride markings. Hand rotation established compression and suction on all cylinders, and valve train continuity was confirmed. Exhaust stacks showed crush damage, and studs on cylinders No. 2 and 4 had pulled away slightly. No evidence of preimpact engine malfunction was found.
Flight control continuity was established from the control wheels to the ailerons and stabilator, but not from the rudder pedals to the rudder. Examination revealed that the rudder bar arm (Part No. 63448-000) and rudder pedal tube (Part No. 65165-053), part of the rudder control assembly (Part No. 66661-000), had separated near a weld. The fracture surface displayed a crack with extensive corrosion. Microscopic examination showed a peak indicative of an initial overload crack that had been open for some time, with corrosion products on one side and fresh substrate on the other from cyclic movements. The right fracture surface also exhibited porosity consistent with a cup-and-cone failure and weld voids.
Maintenance History
Records indicated the airplane was manufactured 53 years before the accident and had accrued about 11,406 hours as of its last 100-hour inspection on January 19, 2021. Piper published multiple inspection requirements for the rudder pedal and bar assembly, including the Piper Cherokee Inspection Report Form, Service Manual Section III-90, Service Letter No. 671 (1973), Service Bulletin No. 1242 (2015), and Service Bulletin No. 1242A (2020). These documents required visual inspections for cracks at intervals depending on time-in-service. The airplane's maintenance records did not contain entries referencing any of these inspections.
Weather and Flight Characteristics
Weather conditions at the time included an approximate 2-knot headwind and a crosswind from the right of about 6 knots. According to flight characteristics data for the PA-28-140, even without rudder, the vertical tail provides directional control to counter left-turning tendencies during takeoff or go-around, though a sideslip creates a rolling moment to the left. Roll can be compensated with right aileron inputs.
Pilot Information
The pilot held a private pilot certificate with ratings for airplane single-engine land and instrument airplane. His most recent FAA third-class medical certificate was issued on June 22, 2020. He reported about 138 total flight hours, with 84 hours in the accident airplane make and model.