Accident Overview
On September 9, 2022, about 1845 eastern daylight time, an Engineering & Research 415-C airplane, registration N99209, was substantially damaged when it collided with a powerline pole during a forced landing on a road near Galion, Ohio. The student pilot, the sole occupant, was not injured. The flight was conducted under Title 14 Code of Federal Regulations Part 91 as a personal flight.
Sequence of Events
According to the student pilot, before departure he conducted an engine run-up that included checking the magnetos and carburetor heat, noting normal rpm decreases. The takeoff roll and initial climb were normal, with the airplane becoming airborne at the usual location. During the upwind leg of the traffic pattern, at about 300 ft above ground level, the engine began to lose power. The pilot lowered the nose to maintain 65 knots and turned left to return to the airport. As the airplane neared the airport, the engine experienced a total loss of power. Realizing the airplane was too high to land on the runway, the pilot flew over and then north of the airport, intending to land on an east/west oriented road. During the landing attempt, the airplane struck a powerline pole and came to rest on the road.
Postaccident Examination
A postaccident examination revealed structural damage to the fuselage and aft empennage. Examination of the engine found that the exhaust valve of the No. 2 cylinder was stuck open.
Maintenance History
Review of the engine maintenance records showed that a reconditioned cylinder was installed at the No. 2 position in March 1990. About 6½ years and 79 hours later, the No. 2 cylinder was removed and the valves were ground. The engine was overhauled in January 1998, with the cylinders honed, and valves ground and lapped. Subsequently, the No. 2 cylinder was removed in 2005 and again in 2009. The 2005 entry noted "stuck valves," while the 2009 entry did not specify a reason. Both entries indicated cleaning and/or reaming of the valve guides. In September 2019, prior to the current owner's acquisition, a "stuck open" exhaust valve of the No. 2 cylinder was reported, with corrective action of reaming the guide and polishing the valve stem. The engine had accrued about 63 hours and nearly 3 years since that last reported exhaust valve incident, and over 32 years and about 628 hours since the reconditioned cylinder was originally installed.
The engine manufacturer's Standard Practice Maintenance Manual stated that the expected repair for a stuck valve included cleaning of the cylinder parts and dimensional checks of the components. The manual did not provide guidance for addressing a repetitive issue.
Additional Information
The airplane was operated as a personal flight with a student pilot at the controls. No injuries were reported.