What happened
On October 6, 2005, at approximately 14:00 local time, a PIPER PA-34-200 Seneca I, registration EC-IHT, was performing a multi-engine pilot training flight at Valencia Airport. During the takeoff roll on runway 12, after reaching $V_1$ speed and at the moment of rotation, the forward baggage door on the left side of the nose detached from the aircraft.
The detached door struck the left engine area and the propeller. The flight instructor, realizing the situation, decided to continue the flight as the remaining runway length was insufficient for a safe rejected takeoff. The instructor reduced engine power and requested an immediate landing. The aircraft landed safely on runway 12 without further incident. Upon parking, the crew discovered that the door had struck the left propeller blades, the left side of the cockpit windscreen, and the rudder.
The investigation
The investigation focused on the condition of the baggage door and its locking mechanism. The door, made of carbon fiber, had torn near its hinge. The investigation examined the maintenance history and the aircraft's compliance with Airworthiness Directives (AD), specifically AD 88-04-05, which was intended to prevent in-flight door openings.
Investigators found that while the aircraft had undergone a 100-hour inspection three days prior, the crew's pre-flight inspection was limited. Because the flight school did not possess the key to the baggage door lock, the crew could only verify the door was secure by pulling on its edges; they could not verify if the handle was actually locked. Furthermore, an examination of another aircraft of the same model operated by the same company revealed that the key could be removed from the lock in positions other than the fully locked position, suggesting a potential issue with lock wear across the fleet.
Findings
- The primary cause of the door opening in flight was excessive wear of the lock and locking system, which failed to guarantee the door remained closed.
- The lack of availability of the door key to the operator and the flight crew prevented a thorough verification of the lock's security during pre-flight inspections.
- Maintenance inspections regarding the door's periodic checks were performed defectively.