ERA12FA280

The pilot's decision to operate the airplane with known electrical system problems, which resulted in the in-flight failure of the electrical wiring interconnect system, loss of electrical power, and subsequent fuel starvation and loss of engine power.

About 2 months before the accident, the homebuilt experimental airplane began to experience electrical problems. This was first discovered when the landing gear hesitated before extending. To extend the landing gear during subsequent flights, the pilot shut off all nonessential electrical equipment in the airplane, extended the landing gear, and then turned the electrical equipment back on. On the morning of the accident, while on approach at the destination airport, the electrical system failed and the landing gear would not extend. The pilot reached behind his seat, "jiggled" the airplane's battery cables, and was able to restore electricity and extend the landing gear. He landed the airplane uneventfully and shut the airplane down. After shutdown, the airplane had to be "hand propped" to be restarted; however, the pilot could not adjust the electrically-controlled propeller to the proper pitch for takeoff. The pilot removed the battery from his airplane and returned to his home airport with another pilot. He charged two batteries and returned with the charged batteries to his airplane. The pilot installed one of the batteries in his airplane and stated that if he could get the airplane started, he would fly it back to his home airport with the landing gear down. The airplane started after three attempts, and the pilot taxied to the runway. A witness observed fuel exiting the right wingtip fuel vent during taxi, indicating that there was fuel in the main wing tanks. The pilot departed, and while he was en route, he transmitted that he was experiencing a problem and that he was going to land in a field. A witness observed the airplane at low altitude but did not hear any engine noise as the airplane passed him. The airplane then maneuvered around a barn and touched down in a level attitude in a harvested corn field. The airplane’s landing gear collapsed, and the airplane nosed over. Examination of the airplane and engine revealed no evidence of any preimpact mechanical failure or malfunction; however, examination of the propeller indicated that the engine was not producing power, and the header tank, which supplied fuel to the engine, contained only 8 ounces of fuel. The inline fuel filter and fuel strainer contained only trace amounts of fuel. Further examination revealed that the header tank received its fuel from the wing tanks via electrically-operated transfer pumps. Examination of a connector that connected the positive battery cable to the master relay revealed that the inside of the connector's collar, which had been soldered and crimped onto the battery cable, was moist and heavily corroded, and that not all of the battery cable's wire strands were in contact with the collar of the connector. Further examination revealed that the end of battery cable that had been retained by the connector's collar was also moist and exhibited significant corrosion, indicating that the connector had been exposed to a corrosive environment. Examination of the battery box revealed corrosion and electrolyte (sulfuric acid) residue, which indicated that a release of electrolyte from a previously-installed battery had occurred. Additionally, comparison of the position of the positive battery cable's run from the battery terminal to the master contactor revealed that the master contactor was mounted below the top of the battery and that no precautions had been taken to prevent liquid from running down the cable into the base of the connector. With a failure of the electrical wiring interconnect, the airplane’s battery was unable to power the electrical system. Because the fuel transfer pumps were electrically powered, fuel was not transferred to the header tank to feed the engine, and a loss of engine power occurred. Additionally, without electrical power, the propeller could not be adjusted and the electrically-actuated landing gear could not be retracted to reduce drag and extend the airplane’s glide. Further, because the wing flaps were electrically operated, they could not be extended during the landing, thus the airplane touched down at a higher speed (13 or more knots) than normal touchdown speed, which reduced the survivability of the accident when the airplane nosed over.

HISTORY OF FLIGHT On April 14, 2012, about 1330 central daylight time, an experimental, amateur-built Lancair 235, N235MW was substantially damaged during a forced landing near Hudson, Kentucky. The private pilot was fatally injured. Visual meteorological conditions prevailed and no flight plan was filed for the Title 14 Code of Federal Regulations Part 91 personal flight, which departed from Rough River State Park Airport (2I3), Falls of Rough, Kentucky, destined for Bowman Field Airport (LOU), Louisville, Kentucky. According to witnesses, approximately 2 months prior to the accident the pilot began to experience electrical issues with the airplane. This was first discovered by him when he went to extend the landing gear on one flight and the landing gear at first did not extend but after hesitating it then extended. This continued to occur every time he flew the airplane, so the pilot would shut off all non essential electrical equipment in the airplane before extending the landing gear and then turn the electrical equipment back on after the landing gear was extended. On the morning of the accident, the pilot flew from LOU to have breakfast with some fellow pilots. On approach to 2I3, he went to extend the landing gear but, the electrical system failed and it would not come down. He then reached behind his seat, jiggled the airplane's battery cables and was able to restore electricity and lower the landing gear. Later when it was time to depart for LOU, he had someone "hand prop" the airplane for him. After it started he could not get the propeller which was electrically controlled and actuated to come out of coarse pitch (low rpm, cruise setting), so that he could take off. He then shut down, removed the battery from his airplane, and returned to LOU with another pilot. Once back at LOU a friend lent him a battery charger. The pilot of the accident airplane then charged up two batteries and rode back to 2I3 in the friend's airplane. The pilot of the accident airplane then installed one of the batteries in his airplane and stated that if he could get it started, he would fly it back to LOU with the landing gear down. His plan, if the radios and electrical system did not work, was for him and his friend to return as a flight of two to LOU. His friend then advised him that if the airplane started but he did not get a positive indication on the "amp gauge" (ammeter) to "shut it down". The pilot then "blew him off". The pilot of the accident airplane tried three times to start the airplane before it finally started. He then waved and gave a "thumbs up" to his friend. After taxing to the runway the pilot stopped the airplane for 6 to 7 seconds and then took off. Prior to the takeoff as the airplane made a turn on the taxiway fuel was observed to come out of the right wingtip vent. His friend then took off, 3 to 4 minutes behind him, and when climbing through 1,700 feet above mean sea level, heard the pilot of the accident airplane ask over the radio if he was still on the frequency. His friend stated that he knew due to the accident pilot's regular phraseology that something was wrong and advised him that he was coming. They were talking on the Unicom frequency for 2I3 and the accident pilot was using a handheld radio rather than the aircraft radios. The accident pilot stated that he was 1 to 2 miles south of Breckinridge County Airport (I93), Hardinsburg, Kentucky and was going to land in a field. His friend responded “I’m coming as fast as I can”. The pilot of the accident airplane then stated “I’m going in hard”. His friend could hear the emergency locator transmitter transmitting. He then circled the area a few times but could not see the accident pilot or airplane, so he landed at I93 and called 911. According to a witness, just prior to the accident, he observed the airplane traveling southeast in a straight line. He could not hear any engine noise. It then disappeared behind a rise in the terrain and then reappeared. The airplane then climbed momentarily, turned right missing a barn, and then disappeared once again behind a rise in the terrain. Moments later the sound of impact was heard. PERSONNEL INFORMATION According to Federal Aviation Administration (FAA) records, the pilot held a private pilot certificate with ratings for airplane single-engine land and instrument airplane. His most recent FAA third-class medical certificate was issued on July 18, 2011. According to pilot records, he had accrued approximately 484 hours of total flight experience. AIRCRAFT INFORMATION The accident aircraft was a single engine, propeller driven, low wing monoplane of composite construction. It was assembled from a kit and was constructed of temperature cured prepreg E-glass skins over a high temperature honey-comb core. The aileron and elevators were controlled through push-pull tubes. The rudder control was via stainless steel cables. It was powered by a 4-cylinder, 118 horsepower, Lycoming O-235-L2C engine equipped with an Ellison EFS-3A throttle body fuel injection system, and a three bladed, MTV-7-F, constant speed, variable pitch propeller. Range was 869 nm. The airplane could cruise at 182 knots, and would stall at 61 knots in the clean configuration (wing flaps up), and would stall at 48 knots with the wing flaps fully extended. It could climb at 1,550 feet per minute. Ceiling was 20,000 feet. Takeoff distance was 1,250 feet and landing distance was 1,380 feet. According to FAA and aircraft maintenance records, the airplane's special airworthiness certificate was issued on February 18, 2006, and it was purchased by the pilot on February 28, 2008. The airplane's most recent conditional inspection was completed on May 11, 2011. At the time of the inspection; the airplane had accrued 238.42 total hours of operation, and the engine had accrued 432.52 hours of operation since major overhaul. METEOROLOGICAL INFORMATION The recorded weather at Godman Army Airfield (FTK), Fort Knox, Kentucky located approximately 23 nautical miles east of the accident site, at 1355, included: winds 180 degrees at 15 knots, 10 miles visibility, broken clouds at 8,500 feet, temperature 24 degrees C, dew point 11 degrees C, and an altimeter setting of 30.04 inches of mercury. WRECKAGE AND IMPACT INFORMATION The airplane after clearing trees that were approximately 30 feet high, struck the ground in a level attitude in a corn field where the corn had already been harvested. The landing gear collapsed and the airplane then traveled 63 feet on a 124 degree heading before nosing over, tumbling, and coming to rest. Examination of the accident site revealed that the majority of the airplane was co-located where the airplane came to rest. The fuselage had broken into three pieces, and both wings had separated from their mounting locations. Multiple lighter pieces of the airplane including the right aileron, left elevator balance weight, left landing gear door, and nose gear door were located along the ground scar that led from the initial impact location to the main wreckage. The canopy and other lighter portions of the airplane and its systems were spread throughout the cornfield. Examination of the cockpit revealed that the magneto switch was in the "BOTH" position, the landing gear handle was in the "DOWN" position, the split rocker master switch was in the "ON" position, and the avionics master switch was in the "ON" position. Both the fuel boost pump and fuel transfer switches were in the "OFF" position. The throttle was found in the full open position, and the mixture control was approximately 1 inch out from the full rich position. The primer was in and locked. Airframe and Flight Controls Examination Examination of the airframe and flight controls did not reveal any evidence of any preimpact failure or malfunction. All of the major components of the airframe wer