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GalinHdz
Joined: 08 Nov 2017 Posts: 150
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Posted: Mon Jun 11, 2018 3:05 pm Post subject: Control Surface Hinge Failure - KIS4 |
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For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
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craneplanes(at)gmail.com Guest
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Posted: Mon Jun 11, 2018 3:34 pm Post subject: Control Surface Hinge Failure - KIS4 |
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Great heads up. Thank you Galin.
(I'm in an Aviation Safety course right now.)
-Doug
On Mon, Jun 11, 2018, 16:07 Galin Hernandez <galinhdz(at)gmail.com> wrote:
[quote] For a while now I noticed that after lubricating my KIS4 control surface
hinges with LPS2, what looked like dirty watery streaks would appear from
all the hinged areas. I thought it was just dirt loosened by the LPS2 and
pushed out by the air stream. But during the recently completed Condition
Inspection, the A&P I used noticed a dark “powder-like” substance around
all the control surface hinges. He indicated it was aluminum powder which
is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old
and has more than 1,250hrs he recommended I consider replacing the hinges
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ftyoder(at)yoderbuilt.com Guest
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Posted: Mon Jun 11, 2018 4:33 pm Post subject: Control Surface Hinge Failure - KIS4 |
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Thanks Galin.
I’ll check my TR 1
Tim
From: owner-kis-list-server(at)matronics.com <owner-kis-list-server(at)matronics.com> On Behalf Of Galin Hernandez
Sent: Monday, June 11, 2018 4:04 PM
To: kis-list(at)matronics.com
Subject: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
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mike(at)vision499.com Guest
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Posted: Mon Jun 11, 2018 7:13 pm Post subject: Control Surface Hinge Failure - KIS4 |
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Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and both saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between the different metals, I know that on our boat we have a problem with aluminum and stainless in close contact with each other
Glad it all ended well
Mike
From: owner-kis-list-server(at)matronics.com [mailto:owner-kis-list-server(at)matronics.com] On Behalf Of Galin Hernandez
Sent: June 11, 2018 4:04 PM
To: kis-list(at)matronics.com
Subject: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
This email has been checked for viruses by Avast antivirus software.
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pastormac62
Joined: 07 Sep 2015 Posts: 71 Location: Indiana
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Posted: Tue Jun 12, 2018 3:21 am Post subject: Control Surface Hinge Failure - KIS4 |
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Hi Galin,Thanks for the heads up!! So glad you’re ok!!
To our success, Stephen McIntosh
On Jun 11, 2018, at 7:03 PM, Galin Hernandez <galinhdz(at)gmail.com (galinhdz(at)gmail.com)> wrote:
Quote: |
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
<20180611_144317[1].jpg>
<20180611_182007[1].jpg>
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GalinHdz
Joined: 08 Nov 2017 Posts: 150
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Posted: Tue Jun 12, 2018 3:29 am Post subject: Control Surface Hinge Failure - KIS4 |
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*"Do you think that the problem could be caused by galvanic reaction
between the different metals, I know that on our boat we have a problem
with aluminum and stainless in close contact with each other."*
Mike - I consider myself fairly good at electronic things but admit I am
poor, at best, with materials so I really don't know. The hinges are
original from before 2001 and I know they are extensively used in certified
airplanes but it could be. I imagine others here, much better qualified
with materials, will provide good input.
On Mon, Jun 11, 2018 at 11:13 PM, <mike(at)vision499.com> wrote:
[quote] Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and
both saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between
the different metals, I know that on our boat we have a problem with
aluminum and stainless in close contact with each other
Glad it all ended well
Mike
*From:* owner-kis-list-server(at)matronics.com [mailto:owner-kis-list-server(at)
matronics.com] *On Behalf Of *Galin Hernandez
*Sent:* June 11, 2018 4:04 PM
*To:* kis-list(at)matronics.com
*Subject:* Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface
hinges with LPS2, what looked like dirty watery streaks would appear from
all the hinged areas. I thought it was just dirt loosened by the LPS2 and
pushed out by the air stream. But during the recently completed Condition
Inspection, the A&P I used noticed a dark “powder-like” substance around
all the control surface hinges. He indicated it was aluminum powder which
is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old
and has more than 1,250hrs he recommended I consider replacing the hinges
| - The Matronics KIS-List Email Forum - | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?KIS-List |
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fredorosa(at)gmail.com Guest
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Posted: Tue Jun 12, 2018 3:52 am Post subject: Control Surface Hinge Failure - KIS4 |
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I foresaw the problem of wear on the aluminum hinges and championed the use of stainless steel hinges. I couldn’t find ss hinges of sufficiently tight tolerances so instead used longer lengths of the aluminum ones. My ailerons, elevator, and rudder had full length hinges. The flaps were getting full length (in several pieces for greater flexibility) hinges also. Of course I don’t know how it all worked out since I sold the project before it ever flew.
I would recommend installing new hinges every so many hours of flying time.
Al ROSA
On Jun 11, 2018, at 11:13 PM, <mike(at)vision499.com (mike(at)vision499.com)> <mike(at)vision499.com (mike(at)vision499.com)> wrote:
Quote: | <![endif]--> <![endif]-->
Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and both saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between the different metals, I know that on our boat we have a problem with aluminum and stainless in close contact with each other
Glad it all ended well
Mike
From: owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com) [mailto:owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com)] On Behalf Of Galin Hernandez
Sent: June 11, 2018 4:04 PM
To: kis-list(at)matronics.com (kis-list(at)matronics.com)
Subject: KIS-List: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
This email has been checked for viruses by Avast antivirus software.
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Robert Reed
Joined: 22 Oct 2009 Posts: 331 Location: Dallas/Ft.Worth
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Posted: Tue Jun 12, 2018 4:45 am Post subject: Control Surface Hinge Failure - KIS4 |
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I didn’t use full length hinges but I more than doubled the size that was called for and placed the mounting screws at strongest point of the hinge every inch. The screws don’t align but the heads are covered anyway. I just didn’t believe the hinges were robust enough based on plans. I also reinforced the hinge pads with additional fiberglass pads.
On the other hand I am still not finished either.
Bob Reed
Sent from my iPhone
On Jun 12, 2018, at 6:49 AM, Alfred Rosa <fredorosa(at)gmail.com (fredorosa(at)gmail.com)> wrote:
Quote: |
I foresaw the problem of wear on the aluminum hinges and championed the use of stainless steel hinges. I couldn’t find ss hinges of sufficiently tight tolerances so instead used longer lengths of the aluminum ones. My ailerons, elevator, and rudder had full length hinges. The flaps were getting full length (in several pieces for greater flexibility) hinges also. Of course I don’t know how it all worked out since I sold the project before it ever flew.
I would recommend installing new hinges every so many hours of flying time.
Al ROSA
On Jun 11, 2018, at 11:13 PM, <mike(at)vision499.com (mike(at)vision499.com)> <mike(at)vision499.com (mike(at)vision499.com)> wrote:
Quote: | <![endif]--> <![endif]-->
Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and both saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between the different metals, I know that on our boat we have a problem with aluminum and stainless in close contact with each other
Glad it all ended well
Mike
From: owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com) [mailto:owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com)] On Behalf Of Galin Hernandez
Sent: June 11, 2018 4:04 PM
To: kis-list(at)matronics.com (kis-list(at)matronics.com)
Subject: KIS-List: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
This email has been checked for viruses by Avast antivirus software.
www.avast.com
[url=#DAB4FAD8-2DD7-40BB-A1B8-4E2AA1F9FDF2] [/url]
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Keith.Miller(at)esa.int Guest
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Posted: Tue Jun 12, 2018 5:26 am Post subject: Control Surface Hinge Failure - KIS4 |
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thanks for the heads up on this one ,
20 odd years ago , my inspector insisted that I fit 3 hinges on the vertical stabalizer just in case this ever happened, i thought it was being over cautious since these are aircraft spec hinges !!, now I know why , and I regret not doing this on all the control surfaces
(See attached file: DSCF0074.jpg)
PLEASE NOTE: the 12 holes in each hinge are not pre machined at the factory, so each hinge could be slightly different in the hole alignment , therefore they need to be drill matched to the same hinge that is being replaced, not difficult but be careful to get them exactly aligned, .
Keith
[img]cid:2__=4EBB0839DFDB95948f9e8a93df938690(at)esa.int[/img]Alfred Rosa ---12/06/2018 13:54:25---I foresaw the problem of wear on the aluminum hinges and championed the use of stainless steel hinge
From: Alfred Rosa <fredorosa(at)gmail.com>
To: kis-list(at)matronics.com
Date: 12/06/2018 13:54
Subject: Re: KIS-List: Control Surface Hinge Failure - KIS4
Sent by: owner-kis-list-server(at)matronics.com
I foresaw the problem of wear on the aluminum hinges and championed the use of stainless steel hinges. I couldn’t find ss hinges of sufficiently tight tolerances so instead used longer lengths of the aluminum ones. My ailerons, elevator, and rudder had full length hinges. The flaps were getting full length (in several pieces for greater flexibility) hinges also. Of course I don’t know how it all worked out since I sold the project before it ever flew.
I would recommend installing new hinges every so many hours of flying time.
Al ROSA
On Jun 11, 2018, at 11:13 PM, <mike(at)vision499.com (mike(at)vision499.com)> <mike(at)vision499.com (mike(at)vision499.com)> wrote:
Thanks for the heads up Galin,
I remember speaking to Vance and Rich about lubricating the hinges and both saying that it was not necessary which did not seem right to me.
Do you think that the problem could be caused by galvanic reaction between the different metals, I know that on our boat we have a problem with aluminum and stainless in close contact with each other
Glad it all ended well
Mike
From:owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com)[mailto:owner-kis-list-server(at)matronics.com (owner-kis-list-server(at)matronics.com)] On Behalf Of Galin Hernandez
Sent:June 11, 2018 4:04 PM
To:kis-list(at)matronics.com (kis-list(at)matronics.com)
Subject:KIS-List: Control Surface Hinge Failure - KIS4
For a while now I noticed that after lubricating my KIS4 control surface hinges with LPS2, what looked like dirty watery streaks would appear from all the hinged areas. I thought it was just dirt loosened by the LPS2 and pushed out by the air stream. But during the recently completed Condition Inspection, the A&P I used noticed a dark “powder-like” substance around all the control surface hinges. He indicated it was aluminum powder which is a sign of the hinges slowly wearing out. Since my airplane is 17yrs old and has more than 1,250hrs he recommended I consider replacing the hinges. I decided this would be done on my next condition inspection and thought nothing of it.
Today, just after departing on a VFR flight from St. Augustine to Ocala, I noticed that applying left rudder had gotten a little hard. Since this was not normal, I aborted the flight and immediately returned to St. Augustine. Once in my hangar I found that the top rudder hinge had come loose, the pin inside the hinge had broken and had somehow fallen out. The rudder was being held in place by the lower hinge and the control rod, neither of which showed any indication of imminent failure. A full inspection of all hinges showed no outward sign of failure to any of them, including the one that just failed. I realized it is difficult, if not impossible to inspect the condition of the pin inside the hinge. I have attached photos of the bottom hinge which shows some of the dark “powder-like” substance.
So if you see a dark “powder-like” substance around your hinges which become dirty watery streaks after lubrication, check the hinges of your control surfaces. Be very thorough with your inspection and replace the hinges if there is any question about their integrity. I am now in the process of replacing all the hinges of my airplane, not just for the rudder but both the ailerons and elevators. Be extra cautious with this since this can easily become a serious safety of flight issue.
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