My most interesting flight so far

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My most interesting flight so far

Postby beaky » Sat Feb 23, 2008 8:46 pm

A thorough write-up will follow, but for the moment I'll just say that Yours Truly is on his third much-needed rum&Coke despite having to work tonight, and feeling very lucky to be alive.

It all started when I took advantage of another lovely Saturday in northern Illinois to head out to C77 and fly in the only rentable C-140 I've heard of so far. Didn't get a proper exterior shot, but she's a beauty, with an O-200 but a lighter GTW than an A model due to the fabric wings. We did a textbook preflight and saw no anomalies, and she had flown that morning... the oil dipstick was still warm.
Here's the office- typical Spartan 140 setup, but oddly enough with a VOR, yet no artificial horizon.

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My CFI for this fam flight, Bob, owns his own C-120 and has a lot of time in this 140... he didn't go easy on me, and I needed that. We went out and did some maneuvers: slow flight,power-off  stalls, steep turns, and some induced secondary stalls- something I haven't done in a while. Two Seven Victor did not disappoint- she's a delight to fly. After we decided to head back for some landings, I asked the CFI to take her for a sec while I took a picture. He suggested he "do something with the airplane" for the pic, and I agreed. He smoothly entered a steep 360, well below the yellow line, and I took this pic.

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An instant after, as I lowered the camera,  it happened. We heard a loud "bang". :o
He immediately leveled the wings and said "what the hell was that?!"
I said "how does it feel? whaddya got?"
"Seems OK, but I've got a lot of right rudder here... wants to yaw left..."

We were about 9 miles from the airport at about 2000 AGL. He called a straight-in for 30, but did not say the "E" word. As we went along, we decided we'd hit a bird, and the rudder, although moving freely, was affected somehow. Or maybe it was the vertical stab. Can't see the tail feathers  from indside a 140, so it was a guess.
The engine was fine. Bob nursed her down to TPA and headed straight for the field.

By the time we got the runway in sight, I was feeling we would be OK (no wind to speak of), but also knew I would not be flying any approaches in 27V that day, so I took a snap of the airport.

Bob made a good landing, and as we taxiied to the ramp we were both champing at the bit to see what the damage was.


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When we got her stopped, a group of airport bums was waiting (someone had seen us land and taxi in)... some staring slack-jawed, some grinning.
Here's why...

Are you ready?
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.sure you're ready? I sure as hell wasn't.... ;D
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TA-DAAAA!!!

Yes, my frends, the entire upper panel of the left wing, from the fuel tank to the wingtip; from the spar cap to the rear spar, was just plain gone. :o :o   :o
The strip of reinforcing tape at the rear edge of the spar cap had also come free, all the way to the root.

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It's a miracle the panel did not just peel back and foul the left aileron, or... (shudder).
It's also a damn good thing Bob immediately started working that rudder for directional control and didn't move the yoke much, or... (double-shudder).

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My pained expression here is due more to the sun being in my eyes than my startling education in the "Fate is the Hunter" factor, but I'll tell you what:
Bob and I both agreed afterwards that if we'd known what the problem really was, we'd have not been so calm about it.
Look at that- it's like frikkin' combat damage!!


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Even more mysterious than what caused the failure (the fabric is relatively new) is how she managed to get us home, despite Bernoulli, Coanda, and Fate itself.... now I really love 140s!!!  :)

... but I'm also more certain I want a 140A with metal wing skins... ;)
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Re: My most interesting flight so far

Postby Jayhawk Jake » Sat Feb 23, 2008 11:41 pm

I'm speechless...and glad that your still here with us! [smiley=guin.gif] <--seems the guy holding a beer has gone missing!
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Re: My most interesting flight so far

Postby Mobius » Sun Feb 24, 2008 12:16 am

Daaannggg. :o


I just don't know what to say.  That's probably something that you couldn't have predicted at all, even with the most thorough preflight you could do.
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Re: My most interesting flight so far

Postby Rifleman » Sun Feb 24, 2008 12:17 am

Nice to see you're still with us Sean.....I know you are too !.....but in retrospect now, I would hazard a guess that you're happy it happened with the CFI with aboard........... :-?
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Re: My most interesting flight so far

Postby beaky » Sun Feb 24, 2008 1:42 am

Daaannggg. :o


I just don't know what to say.  That's probably something that you couldn't have predicted at all, even with the most thorough preflight you could do.


That was my first thought, but I'm still wondering "did I miss a loose strip of tape up there, or any popped staples?"
I did take my usual look, and even tugged at the wings a little as I usually do during preflight, but if I missed any anomalies I might be excused due to so many flights looking for problems with metal wings, not fabric.
 As I recall, it looked pretty good... no patches or anything like that.The last recovering, I found out later, was "fairly recent".
Also, Bob did the preflight with me, to observe my technique... if there was anything fishy, he probably would have seen it.

I'm dying to find out what, if any official analysis is... the owner of the flight school just stared at it with her mouth agape... said she'd never seen anything like that.
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Re: My most interesting flight so far

Postby beaky » Sun Feb 24, 2008 1:46 am

Nice to see you're still with us Sean.....I know you are too !.....but in retrospect now, I would hazard a guess that you're happy it happened with the CFI with aboard........... :-?




As I told another concerned pilot who knows Bob and praised his handling of the situation, I am certain I would have just "rode the SOB down" as Ernie Gann used to say, and not frozen up...I've had to deal with badly-rigged planes that surprised me in the past (although this was another matter entirely).
 But hell yes, it was good to have somebody with me with much more time in type and in airplanes in general!!
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Re: My most interesting flight so far

Postby Hagar » Sun Feb 24, 2008 4:06 am

I've never seen anything like that. :o Never having worked on them I had no idea that Cessna wings are fabric covered.

This should not be possible if the covering was properly done using the old traditional methods. My first thought is that I can't see any sign of stringing round those wing ribs.*

*I've discovered that Cessna apparently use special retaining clips for attaching wing fabric. One is visible in your shot #5. There is a known problem with these working loose.
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Re: My most interesting flight so far

Postby beaky » Sun Feb 24, 2008 4:31 am

I've never seen anything like that. :o I had no idea that the wings are fabric covered.

This should not be possible if the covering was properly done using the old traditional methods. My first thought is that I can't see any sign of stringing round those wing ribs.*

*I've discovered that Cessna apparently use special retaining clips for attaching wing fabric. One is visible in your second shot. There is a known problem with these working loose.
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I've been hoping you'd weigh in before I left for my flight home;
I know you have spent plenty of time around old ragwings, even when they were new. ;)
Good morning. ;D

The 120 and 140s prior to the A model 140 have fabric wings attached with staples that go right thru the aluminum ribs, the ends of the staples being flared outward by some method I don't know.
As far as I can tell, every other aspect is the same as a stitched system: a layer of tape that is bound with the fabric, then another layer on top.
I already had my heart set on a 140A with factory-made metal wings, but this episode made that an absolute must for me. ;D


In any case, this points out the advantage of having a one-piece stitched envelope-type skin that is slipped whole over the wing then fastened in place- had it been that sort of skin, I doubt this would have happened even if some staples let go or the fabric tore.

I think champ wings are done that way, although they also used some sort of fastener instead of stitching.
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Re: My most interesting flight so far

Postby Hagar » Sun Feb 24, 2008 4:53 am

Good morning Sean. ;)

I have no experience with US manufactured aircraft or modern fabric covering methods. I'm familiar with modern covering materials but  things have changed a lot since I last did any fabric work. The traditional methods we used involved hand stitching the fabric along the trailing edge instead of adhesives. Then tape was doped along the ribs with each rib being "strung" through the tape with waxed cord at intervals of about 2 inches. The cord was knotted on the top surface at each joint. This should make it impossible for more than one section of the wing fabric to detach if it were damaged or torn. Of course, we have no idea yet what caused this in your case.

These are the Cessna retaining clips. http://www.aircraftspruce.com/catalog/appages/cessnawfc.php
They might be OK on a new structure but don't look very substantial to me. The use of rivets or PK screws is also approved (also stitching or stringing). I shall inspect any ragwing Cessnas that I see very carefully from now on.

Article on fabric covering on the Ceconite website. http://www.ceconite.com/articlesecuring.htm
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Re: My most interesting flight so far

Postby expat » Sun Feb 24, 2008 4:58 am

Welcome back from the almost dead Sean. This is always the sort of thing you end up seeing third hand on some website or as an emailed Power Point file. Straight from the horses mouth makes a change.
That is quite a tare. I have replaced the fabric of a fare few gliders. Ripping the old off sometimes required some real muscle power. This makes the jaw hit the floor Image ,also a testament to the aircraft and your CFI. You said, "darn good thing Bob immediately started working that rudder for directional control and didn't move the yoke much, or... (double-shudder)". Have you given though to what your reactions would have been if you had been on your own?

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Re: My most interesting flight so far

Postby Omag 2.0 » Sun Feb 24, 2008 5:33 am

Blimey!  :o

Glad to see you down and standing on two feet Sean! That must be an aweful feeling, such an event in mid-air. I think that it was probably for the best you guys didn't see the damage, so you could concentrate on the landing!
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Re: My most interesting flight so far

Postby fulanito_uk » Sun Feb 24, 2008 6:46 am

WOW!!!!!  
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Re: My most interesting flight so far

Postby Roughrider » Sun Feb 24, 2008 7:15 am

Talk about exciting weekends, I glad everything turned out allright, Mark
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Re: My most interesting flight so far

Postby Willit Run » Sun Feb 24, 2008 10:13 am

WOW!!! Sean, I very happy that you were able to post this!!

It's a scarey thought on what could have happened!!  Like you said it was better the two of you didn't know what happen!!

It also shows you what a great little flyer the 140 is if she was able to make it back with a little more effort!!  You can call the her the Cessna P-47!!  :)  She was missing parts and still brough her pilots back safe!!!

Again, I'm damm glad you were able to post this!!!!!!
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Re: My most interesting flight so far

Postby Brett_Henderson » Sun Feb 24, 2008 10:21 am

Holy Moly !

We're always some bizarre airframe failure away from cashing it in, every time we fly... That's a given..

Walking away from one earns you the rare, "been there", badge. Rum&Cokes are on me, in Dayton  ;)

Toasts to both you and Bob  8-)

All I've ever had to "live" through, was some ornery landing gear in a Cardinal; a broken flap linkage in a Warrior (only one side operable), and some alarmingly low oil pressure in a Skyhawk (with a brand new engine in it)...  THAT type of failure might keep me on the ground for a while  :-/
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