[Federal Register Volume 61, Number 168 (Wednesday, August 28, 1996)]
[Rules and Regulations]
[Pages 44157-44160]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 96-21746]


-----------------------------------------------------------------------


DEPARTMENT OF TRANSPORTATION
14 CFR Part 39

[Docket No. 96-CE-36-AD; Amendment 39-9726; AD 96-18-02]
RIN 2120-AA64


Airworthiness Directives; American Champion Aircraft Corporation 
Models 8KCAB, 8GCBC, 7GCBC, 7ECA, 7GCAA, and 7KCAB Airplanes

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule; request for comments.

-----------------------------------------------------------------------

SUMMARY: This amendment supersedes Airworthiness Directive (AD) 96-03-
11, which currently requires the following on American Champion 
Aircraft Corporation (American Champion) Models 8KCAB, 8GCBC, 7GCBC, 
and 7ECA airplanes that are equipped with metal spar wings: inspecting 
(one-time) the wing front strut attach fittings for cracks, scratches, 
or surface deformities; replacing any wing front strut attach fitting 
with cracks, scratches, or surface deformities; and reporting the 
inspection results to the Federal Aviation Administration (FAA). This 
action results from reports submitted as a requirement of the existing 
AD that reference 24 fittings with cracks, scratches, or surface 
deformities on 7 different airplanes, and the FAA's determination that 
improved wing front strut attach fittings (developed by American 
Champion) are not susceptible to cracks, scratches, or surface 
deformities. This action requires installing removable inspection hole 
covers for the wing front strut attach fittings, and replacing the wing 
front strut attach fittings with fittings of improved design. The 
action also provides the provision of repetitively inspecting the wing 
front strut attach fittings (provided no cracks, scratches, or surface 
deformities are found) if parts have been ordered but are not 
available. The actions specified by this AD are intended to prevent 
structural failure of a wing caused by cracked wing front strut attach 
fittings, which, if not detected and corrected, could result in loss of 
control of the airplane.

DATES: Effective September 20, 1996.
    The incorporation by reference of American Champion Service Letter 
409, Revision A, dated April 22, 1996; American Champion Service Letter 
410, dated May 6, 1996; American Champion Service Letter 411, dated May 
6, 1996; American Champion Service Letter 412, dated May 6, 1996; 
American Champion Service Letter 413, dated May 6, 1996, American 
Champion Service Letter 414, Revision A, dated June 25, 1996; and 
American Champion Service Letter 415, Revision A, dated June 25, 1996, 
is approved by the Director of the Federal Register as of September 20, 
1996.
    The incorporation by reference of American Champion Service Letter 
408, dated January 24, 1996, was previously approved as of February 26, 
1991 (61 FR 5501, February 13, 1996) by the Director of the Federal 
Register.
    Comments for inclusion in the Rules Docket must be received on or 
before October 25, 1996.

ADDRESSES: Submit comments in triplicate to the FAA, Central Region, 
Office of the Assistant Chief Counsel, Attention: Rules Docket 96-CE-
36-AD, Room 1558, 601 E. 12th Street, Kansas City, Missouri 64106.
    Service information that applies to this AD may be obtained from 
the American Champion Aircraft Corporation, 32032 Washington Avenue, 
Rochester, Wisconsin 53167. This information may also be examined at 
the FAA, Central Region, Office of the Assistant Chief Counsel, 
Attention: Rules Docket No. 96-CE-36-AD, Room 1558, 601 E. 12th Street, 
Kansas City, Missouri 64106; or at the Office of the Federal Register, 
800 North Capitol Street, NW., suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Ms. Karen Forest, Aerospace Engineer, 
FAA, Chicago Aircraft Certification Office, 2300 E. Devon Avenue, Des 
Plaines, Illinois 60018; telephone (847) 294-7697; facsimile (847) 294-
7834.

SUPPLEMENTARY INFORMATION:

Events Leading to This Action

    On January 31, 1996, the FAA issued AD 96-03-11, Amendment 39-9598 
(61 FR 5501, February 13, 1996), to require the following on American 
Champion Models 8KCAB, 8GCBC, 7GCBC, and 7ECA airplanes that are 
equipped with metal spar wings:

--Inspecting (one-time) the wing front strut attach fittings for 
cracks, scratches, or surface deformities;
--Replacing any wing front strut attach fitting with cracks, scratches, 
or surface deformities; and
--Reporting the inspection results to the FAA.

    AD 96-03-11 resulted from an investigation of an American Champion 
Model 8KCAB airplane accident that revealed fatigue cracking of the 
wing front strut attach fittings. The design of the wing and fuselage 
structure of this airplane is such that the outboard ends of the wing 
fittings for each primary strut are bolted to the web of the wing's 
front spar. One fitting is on the forward side of the web and one is on 
the aft side of the web. The fittings then transition to a wider area 
where the strut is attached with a bolt. On the airplane involved in 
the accident that resulted in AD 96-03-11, the forward fitting 
fractured through the transition area (approximately in the center of 
the fitting length), causing the fitting to separate. This wing front 
strut attach fitting transition area contains an aft leg that is 
assembled against the forward face of the wing spar web and a forward 
leg.
    Investigation of the fitting from the accident aircraft revealed 
that small, sharp scratches in the forward edge of the shorter portion 
of the aft leg contributed to the fatigue cracking in the wing fitting. 
Metallurgical examination of the fitting indicated that these fatigue 
cracks formed in scratches and surface deformities that resulted during 
the manufacturing process, and existed prior to the accident.
    After that accident and prior to issuing AD 96-03-11, the FAA and 
American Champion inspected another Model 8KCAB airplane and found

[[Page 44158]]

fatigue cracks on two of the four wing front strut attach fittings. 
These fatigue cracks also originated from scratches and surface 
deformities in the wing front strut attach fitting. In addition, an 
evaluation of new uninstalled wing front strut attach fittings revealed 
these scratches and surface deformities. American Champion Models 
8GCBC, 7GCBC, and 7ECA airplanes incorporate this same design fitting, 
and thus were included in the Applicability section of AD 96-03-11.
    The results of the inspections required by AD 96-03-11 revealed 24 
wing front strut attach fittings with cracks, scratches, or surface 
deformities. These cracked and scratched fittings were from 7 different 
affected airplanes that had between 103 to 666 total hours time-in-
service.

Improved Design Parts and Service Information

    American Champion has designed improved wing front strut attach 
fittings, part number (P/N) 3-1691 and P/N 3-1692, which, when 
manufactured according to design specifications, will not contain the 
surface deformities and scratches found on the existing design 
fittings. After extensive analysis, these fittings have proven to not 
have the cracking susceptibility of those currently in service. The 
following presents service information that American Champion has 
issued that relates to this issue:
     American Champion Service Letter (SL) 408, dated January 
24, 1996, and American Champion SL 409, Revision A, dated April 22, 
1996, which specify procedures for accessing and inspecting wing front 
strut attach fittings, part number (P/N) 3-1632-1 and P/N 3-1632-2; and 
P/N 3-1646L and 3-1646R, respectively.
     American Champion SL 410, dated May 6, 1996, which 
includes procedures for installing removable inspection hole covers for 
the wing front strut attach fittings on Model 8KCAB airplanes that have 
complied with American Champion SL 408;
     American Champion SL 411, dated May 6, 1996, which 
includes procedures for installing removable inspection hole covers for 
the wing front strut attach fittings on Model 8KCAB airplanes that have 
not complied with American Champion SL 408;
     American Champion SL 412, dated May 6, 1996, which 
specifies procedures for installing removable inspection hole covers 
for the wing front strut attach fittings on Models 7ECA, 7GCAA, 7GCBC, 
and 8GCBC airplanes that have complied with American Champion SL 409;
     American Champion SL 413, dated May 6, 1996, which 
specifies procedures for installing removable inspection hole covers 
for wing front strut attach fittings on Models 7ECA, 7GCAA, 7GCBC, and 
8GCBC airplanes that have not complied with American Champion SL 409.
     American Champion SL 414, Revision A, dated June 25, 1996, 
which specifies procedures for replacing the wing front strut attach 
fittings on Model 8KCAB airplanes with improved wing front strut attach 
fittings, P/N 3-1691, and also includes procedures for inspecting the 
wing front strut attach fittings on these airplanes; and
     American Champion SL 415, Revision A, dated June 25, 1996, 
which specifies procedures for replacing the wing front strut attach 
fittings on Models 8GCBC, 7ECA, 7GCAA, 7GCBC, and 7KCAB airplanes with 
improved wing front strut attach fittings, P/N 3-1692, and also 
includes procedures for inspecting the wing front strut attach fittings 
on these airplanes.

FAA's Determination

    After examining the circumstances and reviewing all available 
information related to the events described above, the FAA has 
determined that (1) The wing front strut attach fittings on American 
Champion Models 8KCAB, 8GCBC, 7ECA, 7GCAA, 7GCBC, and 7KCAB airplanes 
should incorporate P/N 3-1691 and 3-1692, as applicable; and (2) AD 
action should be taken in order to prevent structural failure of a wing 
caused by cracked wing front strut attach fittings, which, if not 
detected and corrected, could result in loss of control of the 
airplane.
    In addition, based on results of an in-depth analysis of the 
existing wing front strut attach fittings, the FAA has determined that 
if the fittings were not replaced with the improved design fittings, 
repetitive inspections would need to be performed at intervals not to 
exceed 20 hours TIS. Allowing repetitive inspections of these airplanes 
over a long period of time goes against FAA policy, which states that 
if a modification exists for critical structure that could eliminate or 
reduce the number of short-term inspections, the modification should be 
incorporated. The FAA makes short-term allowances on this policy to 
account for parts availability provided analysis shows that an 
acceptable level of safety can be maintained through a short-term 
repetitive inspection program.

The Provisions of the Required AD Action

    Since an unsafe condition has been identified that is likely to 
exist or develop in other American Champion Models 8GCBC, 7ECA, 7GCAA, 
7GCBC, and 7KCAB airplanes of the same type design, this AD supersedes 
AD 96-03-11 with a new AD that requires installing removable inspection 
hole covers for the wing front strut attach fittings, and replacing the 
wing front strut attach fittings with P/N 3-1691 (Model 8KCAB) or P/N 
3-1692 (Models 8GCBC, 7ECA, 7GCAA, 7GCBC, and 7KCAB) wing front strut 
attach fittings, as applicable. The FAA is including a provision of 
repetitively inspecting the wing front strut attach fittings (provided 
no cracks, scratches, or surface deformities are found) if parts have 
been ordered but are not available. Accomplishment of these actions is 
in accordance with the service information previously referenced.
    Since a situation exists (structural failure of the wing caused by 
a cracked wing front strut attach fitting) that requires the immediate 
adoption of this regulation, it is found that notice and opportunity 
for prior public comment hereon are impracticable, and that good cause 
exists for making this amendment effective in less than 30 days.

Comments Invited

    Although this action is in the form of a final rule that involves 
requirements affecting immediate flight safety and, thus, was not 
preceded by notice and opportunity to comment, comments are invited on 
this rule. Interested persons are invited to comment on this rule by 
submitting such written data, views, or arguments as they may desire. 
Communications should identify the Rules Docket number and be submitted 
in triplicate to the address specified above. All communications 
received on or before the closing date for comments will be considered, 
and this rule may be amended in light of the comments received. Factual 
information that supports the commenter's ideas and suggestions is 
extremely helpful in evaluating the effectiveness of the AD action and 
determining whether additional rulemaking action would be needed.
    Comments are specifically invited on the overall regulatory, 
economic, environmental, and energy aspects of the rule that might 
suggest a need to modify the rule. All comments submitted will be 
available, both before and after the closing date for comments, in the 
Rules Docket for examination by interested persons. A report that

[[Page 44159]]

summarizes each FAA-public contact concerned with the substance of this 
AD will be filed in the Rules Docket.
    Commenters wishing the FAA to acknowledge receipt of their comments 
submitted in response to this rule must submit a self-addressed, 
stamped postcard on which the following statement is made: ``Comments 
to Docket No. 96-CE-36-AD.'' The postcard will be date stamped and 
returned to the commenter.

Regulatory Impact

    The regulations adopted herein will not have substantial direct 
effects on the States, on the relationship between the national 
government and the States, or on the distribution of power and 
responsibilities among the various levels of government. Therefore, in 
accordance with Executive Order 12612, it is determined that this final 
rule does not have sufficient federalism implications to warrant the 
preparation of a Federalism Assessment.
    The FAA has determined that this regulation is an emergency 
regulation that must be issued immediately to correct an unsafe 
condition in aircraft, and is not a ``significant regulatory action'' 
under Executive Order 12866. It has been determined further that this 
action involves an emergency regulation under DOT Regulatory Policies 
and Procedures (44 FR 11034, February 26, 1979). If it is determined 
that this emergency regulation otherwise would be significant under DOT 
Regulatory Policies and Procedures, a final regulatory evaluation will 
be prepared and placed in the Rules Docket (otherwise, an evaluation is 
not required). A copy of it, if filed, may be obtained from the Rules 
Docket.

List of Subjects in 14 CFR Part 39

    Air transportation, Aircraft, Aviation safety, Incorporation by 
reference, Safety.

Adoption of the Amendment

    Accordingly, pursuant to the authority delegated to me by the 
Administrator, the Federal Aviation Administration amends part 39 of 
the Federal Aviation Regulations (14 CFR part 39) as follows:

PART 39--AIRWORTHINESS DIRECTIVES

    1. The authority citation for part 39 continues to read as follows:

    Authority: 49 U.S.C. 106(g), 40113, 44701.


Sec. 39.13  [Amended]

    2. Section 39.13 is amended by removing AD 96-03-11, Amendment 39-
9598 (61 FR 5501, February 13, 1996), and by adding a new airworthiness 
directive (AD) to read as follows:

96-18-02  American Champion Aircraft Corporation: Amendment 39-9726; 
Docket No. 96-CE-36-AD. Supersedes AD 96-03-11, Amendment 39-9598.

    Applicability: The following airplane models and serial numbers, 
certificated in any category, that are equipped with metal spar 
wings:

--Model 8KCAB airplanes, serial numbers 643-90 through 768-96;
--Model 8KCAB airplanes, all serial numbers, that are equipped with 
metal spar wings, wing assembly part number (P/N) 7-1521 (installed 
in accordance with American Champion Service Kit 403);
--Model 8GCBC airplanes, serial numbers 361-91 through 377-96;
--Model 8GCBC airplanes, all serial numbers, that are equipped with 
metal spar wings, wing assembly part number 7-1542;
--Model 7GCBC airplanes, serial numbers 1200-94 through 1215-96;
--Model 7GCBC airplanes, all serial numbers, that are equipped with 
metal spar wings, wing assembly part number 7-1545;
--Model 7ECA airplanes, serial numbers 1355-95 through 1358-96; and
--Models 7ECA, 7GCCA, and 7KCAB airplanes, all serial numbers, that 
are equipped with metal spar wings, wing assembly part number 7-
1567.

    Note 1: This AD applies to each airplane identified in the 
preceding applicability provision, regardless of whether it has been 
modified, altered, or repaired in the area subject to the 
requirements of this AD. For airplanes that have been modified, 
altered, or repaired so that the performance of the requirements of 
this AD is affected, the owner/operator must request approval for an 
alternative method of compliance in accordance with paragraph (f) of 
this AD. The request should include an assessment of the effect of 
the modification, alteration, or repair on the unsafe condition 
addressed by this AD; and, if the unsafe condition has not been 
eliminated, the request should include specific proposed actions to 
address it.

    Compliance: Required within the next 20 hours time-in-service 
(TIS) after the effective date of this AD, unless already 
accomplished.
    To prevent structural failure of a wing assembly caused by 
cracked wing front strut attach fittings, which, if not detected and 
corrected, could result in loss of control of the airplane, 
accomplish the following:
    (a) Install removable inspection hole openings for the wing 
front strut attach fittings in accordance with one of the following, 
as applicable:
    (1) American Champion Service Letter (SL) 410, dated May 6, 
1996, for Model 8KCAB airplanes that have complied with American 
Champion SL 408, dated January 24, 1996;
    (2) American Champion SL 411, dated May 6, 1996, for Model 8KCAB 
airplanes that have not complied with American Champion SL 408, 
dated January 24, 1996;
    (3) American Champion SL 412, dated May 6, 1996, for Models 
7ECA, 7GCAA, 7GCBC, and 8GCBC airplanes that have complied with 
American Champion SL 409, Revision A, dated April 22, 1996; and
    (4) American Champion SL 413, dated May 6, 1996, for Models 
7ECA, 7GCAA, 7GCBC, and 8GCBC airplanes that have not complied with 
American Champion SL 409, Revision A, dated April 22, 1996.

    Note 2: American Champion SL 408 and American Champion SL 409, 
when complied with, incorporate permanent inspection holes for 
access to the wing front strut attach fittings, P/N 3-1632-1 and P/N 
3-1632-2; and P/N 3-1646L and 3-1646R, respectively.

    (b) Replace the wing front strut attach fittings with P/N 3-1691 
(Model 8KCAB) or P/N 3-1692 (Models 8GCBC, 7ECA, 7GCAA, 7GCBC, and 
7KCAB) wing front strut attach fittings, as applicable. 
Accomplishment of these actions is required in accordance with the 
instructions in American Champion SL 414, Revision A, dated June 25, 
1996; or American Champion SL 415, Revision A, dated June 25, 1996, 
as applicable.
    (c) If the improved design wing front strut attach fittings 
referenced in paragraph (b) have been ordered from the manufacturer, 
but are not available, repetitively inspect the wing front strut 
attach fittings for cracks, scratches, or surface deformities at 
intervals not to exceed 20 hours TIS in accordance with the 
instructions in American Champion SL 408, dated January 24, 1996, or 
American Champion SL 409, Revision A, dated April 22, 1996, as 
applicable. Figure 3 of these service letters depicts the 
crosshatched areas of the fittings that must be inspected. These 
service letters also specify both a visual inspection and the choice 
of either a dye penetrant, Zyglo test, ultrasonic, or x-ray 
inspection.
    (d) The repetitive inspections allowed in paragraph (c) of this 
AD may be continued until one of the following occurs at which time 
the replacement required by paragraph (b) of this AD must be 
accomplished prior to further flight:
    (1) Cracks, scratches, or surface deformities are found on a 
wing front strut attach fitting;
    (2) Parts become available from the American Champion Aircraft 
Corporation; or
    (3) Six repetitive inspection intervals are accomplished (120 
hours TIS).
    (e) Special flight permits may be issued in accordance with 
sections 21.197 and 21.199 of the Federal Aviation Regulations (14 
CFR 21.197 and 21.199) to operate the airplane to a location where 
the requirements of this AD can be accomplished.
    (f) An alternative method of compliance or adjustment of the 
initial or repetitive compliance time that provides an equivalent 
level of safety may be approved by the Manager, Chicago Aircraft 
Certification Office (ACO), 2300 E. Devon Avenue, Des Plaines, 
Illinois 60018. The request shall be forwarded through an 
appropriate FAA Maintenance Inspector, who may add comments and then 
send it to the Manager, Chicago ACO. Alternative methods of 
compliance approved in accordance with AD 96-03-11 (superseded by 
this action), are not considered approved as alternative methods of 
compliance for this AD.


[[Page 44160]]


    Note 3: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Chicago ACO.

    (g) The incorporation of certain documents referenced in this AD 
is as follows:
    (1) The installations required by this AD shall be done in 
accordance with American Champion Service Letter 410, dated May 6, 
1996; American Champion Service Letter 411, dated May 6, 1996; 
American Champion Service Letter 412, dated May 6, 1996; or American 
Champion Service Letter 413, dated May 6, 1996, as applicable. This 
incorporation by reference was approved by the Director of the 
Federal Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 
51.
    (2) The replacements required by this AD shall be accomplished 
in accordance with American Champion Service Letter 414, Revision A, 
dated June 25, 1996; or American Champion Service Letter 415, 
Revision A, dated June 25, 1996, as applicable. This incorporation 
by reference was approved by the Director of the Federal Register in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51.
    (3) The inspections (if parts are not available) required by 
this AD shall be accomplished in accordance with American Champion 
Service Letter 408, dated January 24, 1996, or American Champion 
Service Letter 409, Revision A, dated April 22, 1996.
    (i) The incorporation by reference of American Champion Service 
Letter 408 reference was previously approved as of February 26, 1996 
(61 FR 5501, February 13, 1996) by the Director of the Federal 
Register in accordance with 5 U.S.C. 552(a) and 1 CFR part 51.
    (ii) The incorporation by reference of American Champion Service 
Letter 409 was approved by the Director of the Federal Register in 
accordance with 5 U.S.C. 552(a) and 1 CFR part 51.
    (4) Copies may be obtained from the American Champion Aircraft 
Corporation, 32032 Washington Avenue, Rochester, Wisconsin 53167. 
Copies may be inspected at the FAA, Central Region, Office of the 
Assistant Chief Counsel, Room 1558, 601 E. 12th Street, Kansas City, 
Missouri, or at the Office of the Federal Register, 800 North 
Capitol Street, NW., suite 700, Washington, DC.
    (h) This amendment (39-9726) supersedes AD 96-03-11, Amendment 
39-9598.
    (i) This amendment (39-9726) becomes effective on September 20, 
1996.

    Issued in Kansas City, Missouri, on August 20, 1996.
Michael Gallagher,
Manager, Small Airplane Directorate, Aircraft Certification Service.
[FR Doc. 96-21746 Filed 8-27-96; 8:45 am]
BILLING CODE 4910-13-U