(reproduced here from front page of VansAirForce.net for archives/discussion)
DON’T MAKE THIS MISTAKE!!!!!
WE WERE LUCKY!!!!
By Roger H. "Woodman"
I wasn’t going to tell the community about this situation fearing it would make me look foolish. However, it provides an excellent and uncommon educational moment, so here goes.
About two months ago my best buddy was taking a friend of his for a ride in our airplane when, on takeoff, he ran into a flock of blackbirds. They heard a bang and knew a bird had been struck. After leveling off, they observed feathers and feet waving in the wind near the right wingtip. Everything felt OK so the flight was resumed with no sign of anything wrong. After landing, they discovered that one bird had impacted directly on the lens of the Duckworks taxi light. It shattered the lens and bulb but didn’t hit any aluminum at all. We ordered a new lens and bulb and replaced what had been broken. Everything was cleaned up and the new bulb and lens were replaced.
About a month later my wife and I were getting ready to go flying. My Sweetie did a thorough preflight inspection and everything was in good order. I should mention that after the lens was replaced my friend and I logged at least a half dozen flights.
As Myra and I were taxiing to the active runway, I moved the stick in all directions, as I routinely do, and found that the ailerons were literally LOCKED AND WOULD NOT MOVE. We shut down and I proceeded to identify the problem. I tried to move the ailerons by hand while standing next to the wing and they would not budge. I was able to get a little movement and I heard a slight clicking sound coming from the right wing. I kept inspecting and could not find what was causing the noise or the frozen condition. As I moved towards the wingtip the click became louder and I noticed a reflection between the wingtip and the aileron. A PIECE OF PLASTIC FROM THE BROKEN LENS HAD WORKED ITS WAY FROM THE LEADING EDGE, OVER A RIB AND SLID DOWN BETWEEN THE WINGTIP AND AILERON. It had wedged itself at the very aft part of the two surfaces and locked the ailerons. WOW! I removed the plastic and tapped with the palm of my hand on the bottom surface of the wingtip to see if I could hear anything else rattling inside. There was n
o sound so I assumed that it was just one piece that made its way past the lens reflector and into the wing. My Sweetie said, “What makes you think there aren’t any more pieces in the wingtip?” Mistake number two. We flew to our”must get to” fly-in, fortunately, with no further incident and glad that this happened on the ground.
The following day I told my friend of the experience and he related to me that about a week prior when he took the plane up for a solo flight he felt a momentary sticking and assumed the seat belt on the right seat had become wedged near the control stick. He moved the belt and all was normal. When I explained what had happened the day before, he immediately began taking screws out of the wingtip. WE FOUND AT LEAST A DOZEN MORE PIECES OF PLASTIC inside the wingtip and between the two most outboard ribs. We removed what we could see by hand and then vacuumed as much as we could reach until we were sure all debris was removed. The lesson here is if ever you have something go wrong, carefully examine every area that could be affected and do not leave anything to chance. Disassemble parts if you have to. We didn’t think anything could have passed the reflector in the back of the light but when we looked closer after the this incident we saw there is a ¼” space at the very top of the reflector that is not readily
visible when looking at the lens straight on.
The photos depict how the plastic was wedged in the wingtip. I painted it for the pictures. Because it is made of clear plastic it is almost impossible to see until it caused a problem. WHAT WOULD YOU DO?
Woodman (Roger H.).
DON’T MAKE THIS MISTAKE!!!!!
WE WERE LUCKY!!!!
By Roger H. "Woodman"
I wasn’t going to tell the community about this situation fearing it would make me look foolish. However, it provides an excellent and uncommon educational moment, so here goes.
About two months ago my best buddy was taking a friend of his for a ride in our airplane when, on takeoff, he ran into a flock of blackbirds. They heard a bang and knew a bird had been struck. After leveling off, they observed feathers and feet waving in the wind near the right wingtip. Everything felt OK so the flight was resumed with no sign of anything wrong. After landing, they discovered that one bird had impacted directly on the lens of the Duckworks taxi light. It shattered the lens and bulb but didn’t hit any aluminum at all. We ordered a new lens and bulb and replaced what had been broken. Everything was cleaned up and the new bulb and lens were replaced.
About a month later my wife and I were getting ready to go flying. My Sweetie did a thorough preflight inspection and everything was in good order. I should mention that after the lens was replaced my friend and I logged at least a half dozen flights.
As Myra and I were taxiing to the active runway, I moved the stick in all directions, as I routinely do, and found that the ailerons were literally LOCKED AND WOULD NOT MOVE. We shut down and I proceeded to identify the problem. I tried to move the ailerons by hand while standing next to the wing and they would not budge. I was able to get a little movement and I heard a slight clicking sound coming from the right wing. I kept inspecting and could not find what was causing the noise or the frozen condition. As I moved towards the wingtip the click became louder and I noticed a reflection between the wingtip and the aileron. A PIECE OF PLASTIC FROM THE BROKEN LENS HAD WORKED ITS WAY FROM THE LEADING EDGE, OVER A RIB AND SLID DOWN BETWEEN THE WINGTIP AND AILERON. It had wedged itself at the very aft part of the two surfaces and locked the ailerons. WOW! I removed the plastic and tapped with the palm of my hand on the bottom surface of the wingtip to see if I could hear anything else rattling inside. There was n
o sound so I assumed that it was just one piece that made its way past the lens reflector and into the wing. My Sweetie said, “What makes you think there aren’t any more pieces in the wingtip?” Mistake number two. We flew to our”must get to” fly-in, fortunately, with no further incident and glad that this happened on the ground.
The following day I told my friend of the experience and he related to me that about a week prior when he took the plane up for a solo flight he felt a momentary sticking and assumed the seat belt on the right seat had become wedged near the control stick. He moved the belt and all was normal. When I explained what had happened the day before, he immediately began taking screws out of the wingtip. WE FOUND AT LEAST A DOZEN MORE PIECES OF PLASTIC inside the wingtip and between the two most outboard ribs. We removed what we could see by hand and then vacuumed as much as we could reach until we were sure all debris was removed. The lesson here is if ever you have something go wrong, carefully examine every area that could be affected and do not leave anything to chance. Disassemble parts if you have to. We didn’t think anything could have passed the reflector in the back of the light but when we looked closer after the this incident we saw there is a ¼” space at the very top of the reflector that is not readily
visible when looking at the lens straight on.
The photos depict how the plastic was wedged in the wingtip. I painted it for the pictures. Because it is made of clear plastic it is almost impossible to see until it caused a problem. WHAT WOULD YOU DO?
Woodman (Roger H.).
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