McCauley Pucker Factor

[Orval Fairbairn]

This past Monday, a couple of my friends took off in a Bonanza with a
3-blade McCauley prop installed. At about 1000 feet, on power
reduction, one of the blades came unhooked from its pitch change
mechanism and went into "free pitch" mode.

It apparently made a lot of racket and bad vibrations right away; they
were able to make a 180 and land downwind safely. They even had a hard
time taxiing, but all are safe.

Both McCauley and the FAA are really interested in this one -- to make
sure that proper overhaul procedures were followed and to ascertain
whether or not bogus parts were used.

The insurance company is paying for the engine teardown/rebuild, as
there is a possibility that the front bearing was damaged, due to
asymmetric thrust.

The fortunate thing is that it happened at 1000 feet, after takeoff from
a 4800 ft runway, lightly loaded.

Watch this space for possible AD and other stuff hitting the fan.

[zatatime]

On Fri, 14 May 2004 03:01:09 GMT, Orval Fairbairn
> wrote:

>This past Monday, a couple of my friends took off in a Bonanza with a
>3-blade McCauley prop installed. At about 1000 feet, on power
>reduction, one of the blades came unhooked from its pitch change
>mechanism and went into "free pitch" mode.
>
>It apparently made a lot of racket and bad vibrations right away; they
>were able to make a 180 and land downwind safely. They even had a hard
>time taxiing, but all are safe.
>
>Both McCauley and the FAA are really interested in this one -- to make
>sure that proper overhaul procedures were followed and to ascertain
>whether or not bogus parts were used.
>
>The insurance company is paying for the engine teardown/rebuild, as
>there is a possibility that the front bearing was damaged, due to
>asymmetric thrust.
>
>The fortunate thing is that it happened at 1000 feet, after takeoff from
>a 4800 ft runway, lightly loaded.
>
>Watch this space for possible AD and other stuff hitting the fan.


Was it a metal prop, or one of those new composite ones?

z

[Jay Honeck]

> This past Monday, a couple of my friends took off in a Bonanza with a
> 3-blade McCauley prop installed. At about 1000 feet, on power
> reduction, one of the blades came unhooked from its pitch change
> mechanism and went into "free pitch" mode.

Wow -- I can't imagine how a blade could come detached. Those are some
pretty beefy mechanisms.

Glad they're all safe.
--
Jay Honeck
Iowa City, IA
Pathfinder N56993
www.AlexisParkInn.com
"Your Aviation Destination"

[Orval Fairbairn]

In article <haapc.2474$qA.269328@attbi_s51>,
"Jay Honeck" > wrote:

> > This past Monday, a couple of my friends took off in a Bonanza with a
> > 3-blade McCauley prop installed. At about 1000 feet, on power
> > reduction, one of the blades came unhooked from its pitch change
> > mechanism and went into "free pitch" mode.
>
> Wow -- I can't imagine how a blade could come detached. Those are some
> pretty beefy mechanisms.
>
> Glad they're all safe.


I saw the prop in a friend's hangar -- you could rotate one blade freely
about its longitudinal axis, while the other two were normal.

[Orval Fairbairn]

In article >,
zatatime > wrote:

> On Fri, 14 May 2004 03:01:09 GMT, Orval Fairbairn
> > wrote:
>
> >This past Monday, a couple of my friends took off in a Bonanza with a
> >3-blade McCauley prop installed. At about 1000 feet, on power
> >reduction, one of the blades came unhooked from its pitch change
> >mechanism and went into "free pitch" mode.
> >
> >It apparently made a lot of racket and bad vibrations right away; they
> >were able to make a 180 and land downwind safely. They even had a hard
> >time taxiing, but all are safe.
> >
> >Both McCauley and the FAA are really interested in this one -- to make
> >sure that proper overhaul procedures were followed and to ascertain
> >whether or not bogus parts were used.
> >
> >The insurance company is paying for the engine teardown/rebuild, as
> >there is a possibility that the front bearing was damaged, due to
> >asymmetric thrust.
> >
> >The fortunate thing is that it happened at 1000 feet, after takeoff from
> >a 4800 ft runway, lightly loaded.
> >
> >Watch this space for possible AD and other stuff hitting the fan.
>
>
> Was it a metal prop, or one of those new composite ones?
>
> z

Metal -- you could rotate one blade freelt about its longitudinal axis.
I was told that there is a Mickey Mouse setup within the hub that locks
the blades together. I also understand that teardown is Monday, under
FAA supervision.

[Tom Jackson]

What I find hard to believe, is that the insurance co. is willing to pay for
the tear-down.

Don't they only normally pay for incidental damage - i.e., a tear-down after
a prop-strike?

"Orval Fairbairn" > wrote in message
...
> This past Monday, a couple of my friends took off in a Bonanza with a
> 3-blade McCauley prop installed. At about 1000 feet, on power
> reduction, one of the blades came unhooked from its pitch change
> mechanism and went into "free pitch" mode.
>
> It apparently made a lot of racket and bad vibrations right away; they
> were able to make a 180 and land downwind safely. They even had a hard
> time taxiing, but all are safe.
>
> Both McCauley and the FAA are really interested in this one -- to make
> sure that proper overhaul procedures were followed and to ascertain
> whether or not bogus parts were used.
>
> The insurance company is paying for the engine teardown/rebuild, as
> there is a possibility that the front bearing was damaged, due to
> asymmetric thrust.
>
> The fortunate thing is that it happened at 1000 feet, after takeoff from
> a 4800 ft runway, lightly loaded.
>
> Watch this space for possible AD and other stuff hitting the fan.

[[email protected]]

On Sat, 15 May 2004 01:47:29 GMT, "Tom Jackson" >
wrote:

>What I find hard to believe, is that the insurance co. is willing to pay for
>the tear-down.
>
>Don't they only normally pay for incidental damage - i.e., a tear-down after
>a prop-strike?

In the cases that I have been exposed to, the insurance company will
pay for a sudden-stoppage inspection "by-the-book", i.e. they will pay
the mandatory replacement parts and labor to perform the
manufacturer's required inspection.

They will also typically pay to repair internal damage that has
directly resulted from the incident. But any other issues discovered
during the inspection (parts worn beyond limits from normal usage) are
on the owner's dime.

I would expect it would be the same in this case.

TC

[zatatime]

On Fri, 14 May 2004 21:29:38 GMT, Orval Fairbairn
> wrote:

>In article >,
> zatatime > wrote:
>
>> On Fri, 14 May 2004 03:01:09 GMT, Orval Fairbairn
>> > wrote:
>>
>> >This past Monday, a couple of my friends took off in a Bonanza with a
>> >3-blade McCauley prop installed. At about 1000 feet, on power
>> >reduction, one of the blades came unhooked from its pitch change
>> >mechanism and went into "free pitch" mode.
>> >
>> >It apparently made a lot of racket and bad vibrations right away; they
>> >were able to make a 180 and land downwind safely. They even had a hard
>> >time taxiing, but all are safe.
>> >
>> >Both McCauley and the FAA are really interested in this one -- to make
>> >sure that proper overhaul procedures were followed and to ascertain
>> >whether or not bogus parts were used.
>> >
>> >The insurance company is paying for the engine teardown/rebuild, as
>> >there is a possibility that the front bearing was damaged, due to
>> >asymmetric thrust.
>> >
>> >The fortunate thing is that it happened at 1000 feet, after takeoff from
>> >a 4800 ft runway, lightly loaded.
>> >
>> >Watch this space for possible AD and other stuff hitting the fan.
>>
>>
>> Was it a metal prop, or one of those new composite ones?
>>
>> z
>
>Metal -- you could rotate one blade freelt about its longitudinal axis.
>I was told that there is a Mickey Mouse setup within the hub that locks
>the blades together. I also understand that teardown is Monday, under
>FAA supervision.


Thanks. I know most props aren't overbuilt. I'm very curious to see
what takes place over time with the new prop blades that are being
made.

Hope they find the root cause, and that it doesn't warrant an AD.

z

[Orval Fairbairn]

In article >,
zatatime > wrote:

> On Fri, 14 May 2004 21:29:38 GMT, Orval Fairbairn
> > wrote:
>
> >In article >,
> > zatatime > wrote:
> >
> >> On Fri, 14 May 2004 03:01:09 GMT, Orval Fairbairn
> >> > wrote:
> >>
> >> >This past Monday, a couple of my friends took off in a Bonanza with a
> >> >3-blade McCauley prop installed. At about 1000 feet, on power
> >> >reduction, one of the blades came unhooked from its pitch change
> >> >mechanism and went into "free pitch" mode.
> >> >
> >> >It apparently made a lot of racket and bad vibrations right away; they
> >> >were able to make a 180 and land downwind safely. They even had a hard
> >> >time taxiing, but all are safe.
> >> >
> >> >Both McCauley and the FAA are really interested in this one -- to make
> >> >sure that proper overhaul procedures were followed and to ascertain
> >> >whether or not bogus parts were used.
> >> >
> >> >The insurance company is paying for the engine teardown/rebuild, as
> >> >there is a possibility that the front bearing was damaged, due to
> >> >asymmetric thrust.
> >> >
> >> >The fortunate thing is that it happened at 1000 feet, after takeoff from
> >> >a 4800 ft runway, lightly loaded.
> >> >
> >> >Watch this space for possible AD and other stuff hitting the fan.
> >>
> >>
> >> Was it a metal prop, or one of those new composite ones?
> >>
> >> z
> >
> >Metal -- you could rotate one blade freelt about its longitudinal axis.
> >I was told that there is a Mickey Mouse setup within the hub that locks
> >the blades together. I also understand that teardown is Monday, under
> >FAA supervision.
>
>
> Thanks. I know most props aren't overbuilt. I'm very curious to see
> what takes place over time with the new prop blades that are being
> made.
>
> Hope they find the root cause, and that it doesn't warrant an AD.
>
> z

Current thinking is that the prop shop that did the O/H did not follow
McCauley procedures -- we will find out more on Monday, when they tear
down the prop. BTW, they could not even taxi the plane -- it had too
much vibration and not enough net thrust.

[MichaelR]

If the insurance company finds that the prop was improperly overhauled, they
might sue the shop that did it to get their money back.



"Tom Jackson" > wrote in message
news:REepc.94896$Ik.7314393@attbi_s53...
> What I find hard to believe, is that the insurance co. is willing to pay
for
> the tear-down.
>
> Don't they only normally pay for incidental damage - i.e., a tear-down
after
> a prop-strike?
>

[Orval Fairbairn]

In article
>
,
Orval Fairbairn > wrote:

> This past Monday, a couple of my friends took off in a Bonanza with a
> 3-blade McCauley prop installed. At about 1000 feet, on power
> reduction, one of the blades came unhooked from its pitch change
> mechanism and went into "free pitch" mode.
>
> It apparently made a lot of racket and bad vibrations right away; they
> were able to make a 180 and land downwind safely. They even had a hard
> time taxiing, but all are safe.
>
> Both McCauley and the FAA are really interested in this one -- to make
> sure that proper overhaul procedures were followed and to ascertain
> whether or not bogus parts were used.
>
> The insurance company is paying for the engine teardown/rebuild, as
> there is a possibility that the front bearing was damaged, due to
> asymmetric thrust.
>
> The fortunate thing is that it happened at 1000 feet, after takeoff from
> a 4800 ft runway, lightly loaded.
>
> Watch this space for possible AD and other stuff hitting the fan.


Followup:

I talked to the owner of the plane today -- he was present when they
opened up the prop hub.

The pin at the base of the blade had sheared off. This is about 1/2"
diameter and keeps the blade synchronized with the other blades. The pin
went off for metallurgical analysis -- it was either too brittle or had
improper heat treatment done, so there may be no joy in Mudville after
this one is done.

I wonder how many accidents have happened where the pin had broken and
was dismissed as accident damage, rather than accident cause.

[Bob Chilcoat]

Why do I smell an expensive AD coming?

--
Bob (Chief Pilot, White Knuckle Airways)

I don't have to like Bush and Cheney (Or Kerry, for that matter) to love
America

"Orval Fairbairn" > wrote in message
.
...
> In article
> >
> ,
> Orval Fairbairn > wrote:
>
> > This past Monday, a couple of my friends took off in a Bonanza with a
> > 3-blade McCauley prop installed. At about 1000 feet, on power
> > reduction, one of the blades came unhooked from its pitch change
> > mechanism and went into "free pitch" mode.
> >
> > It apparently made a lot of racket and bad vibrations right away; they
> > were able to make a 180 and land downwind safely. They even had a hard
> > time taxiing, but all are safe.
> >
> > Both McCauley and the FAA are really interested in this one -- to make
> > sure that proper overhaul procedures were followed and to ascertain
> > whether or not bogus parts were used.
> >
> > The insurance company is paying for the engine teardown/rebuild, as
> > there is a possibility that the front bearing was damaged, due to
> > asymmetric thrust.
> >
> > The fortunate thing is that it happened at 1000 feet, after takeoff from
> > a 4800 ft runway, lightly loaded.
> >
> > Watch this space for possible AD and other stuff hitting the fan.
>
>
> Followup:
>
> I talked to the owner of the plane today -- he was present when they
> opened up the prop hub.
>
> The pin at the base of the blade had sheared off. This is about 1/2"
> diameter and keeps the blade synchronized with the other blades. The pin
> went off for metallurgical analysis -- it was either too brittle or had
> improper heat treatment done, so there may be no joy in Mudville after
> this one is done.
>
> I wonder how many accidents have happened where the pin had broken and
> was dismissed as accident damage, rather than accident cause.

[Bill Hale]

Orval Fairbairn > wrote in message >...
> This past Monday, a couple of my friends took off in a Bonanza with a
> 3-blade McCauley prop installed. At about 1000 feet, on power
> reduction, one of the blades came unhooked from its pitch change
> mechanism and went into "free pitch" mode.

There is a composite material link between the pitch change mechanism
and the blade acutator pin, which is on the circumference of the blade
shank. It's about 2" long.

This is a reason that McCauley specifically warns against pulling the
airplane with the prop while on the ground. If you pull on the back
edge of the blade, you can put enough torque on it to threaten the links.

Ond does wonder how they were cared for because this is a very rare
failure.

It would be like a terrible mistrack on a helicopter rotor.

Bill Hale BPPP Instructor