Incident Description
On October 13, 2004, at approximately 16:00 local time, a Piper PA-34-200T, registration EC-FMX, was performing a takeoff roll on runway 26 at Casarrubios del Monte airfield (Toledo, Spain). The aircraft had arrived earlier for brake system maintenance. After satisfactory ground checks, the pilot decided to return to its home base at Madrid/Cuatro Vientos Airport. During the takeoff roll, after about 80 meters, the nose gear collapsed, causing the forward fuselage to drop. Both propellers and the nose struck the pavement. The aircraft skidded on its forward fuselage for another 80 meters before stopping on the runway.
Occupants and Injuries
Neither of the two occupants (pilot and one passenger) were injured and they evacuated the aircraft without assistance.
Aircraft Damage
The aircraft sustained substantial damage to both propellers (which were at full power at impact), the fuselage, and the nose gear.
Pilot Information
The pilot, aged 25, held a commercial pilot license and had 874 total flight hours, including 144 hours on type. In the previous 90 days, he had flown 83 hours; in the previous 30 days, 11 hours; and had no flight time in the last 24 hours.
Aircraft and Maintenance History
The aircraft had a valid airworthiness certificate until July 19, 2004. It had previously suffered a nose gear mount failure on August 2, 2003, at Son Bonet airfield, after which it underwent extensive repairs from August 2003 to June 2004. Those repairs included installation of a new nose gear mount and other items. A 100-hour inspection was performed on August 30, 2004.
Nose Gear Examination
After the incident, the nose gear was visually inspected while the aircraft was jacked. The overcenter link did not reach its correct position, leaving the gear unlocked. This was traced to the downlock link (part number 40) being shorter than required. Further inspection found that the threaded rod connecting the link to the overcenter was bent near its head, likely from the collapse. Despite three green down-lock lights in the cockpit, the nose gear was not securely locked. Attempts to manually retract the gear failed due to hydraulic system protection valves.
Runway Condition
The runway (08-26, 600 m long, 18 m wide) was inspected near threshold 26. It showed numerous irregularities: potholes, asphalt ridges, and deep cracks. However, the report does not attribute the collapse directly to the runway condition.
Probable Cause
The nose gear did not lock properly because the length of the downlock link (element 40) was shorter than necessary.