[Federal Register Volume 64, Number 168 (Tuesday, August 31, 1999)]
[Rules and Regulations]
[Pages 47362-47365]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 99-22077]


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DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. 98-SW-72-AD; Amendment 39-11268; AD 99-18-02]
RIN 2120-AA64


Airworthiness Directives; Bell Helicopter Textron, Inc. Model 
205A-1 and 205B Helicopters

AGENCY: Federal Aviation Administration, DOT.

ACTION: Final rule.

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SUMMARY: This amendment adopts a new airworthiness directive (AD), 
applicable to Bell Helicopter Textron, Inc. (BHTI) Model 205A-1 and 
205B helicopters, that requires inspecting the vertical fin spar cap 
(spar cap) for cracking, corrosion, or disbonding; modifying the 
vertical fin; and replacing the left-hand spar cap. This amendment is 
prompted by five accidents involving helicopters of similar type 
design. The actions specified by this AD are intended to detect fatigue 
cracking or corrosion on the spar cap, which could lead to failure of 
the vertical fin spar, loss of the tail rotor, and subsequent loss of 
control of the helicopter.

DATES: Effective October 5, 1999.
    The incorporation by reference of certain publications listed in 
the regulations is approved by the Director of the Federal Register as 
of October 5, 1999.

ADDRESSES: The service information referenced in this AD may be 
obtained from Bell Helicopter Textron, Inc., P.O. Box 482, Fort Worth, 
Texas 76101, telephone (817) 280-3391, fax (817) 280-6466. This 
information may be examined at the FAA, Office of the Regional Counsel, 
Southwest Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas; or 
at the Office of the Federal Register, 800 North Capitol Street, NW., 
suite 700, Washington, DC.

FOR FURTHER INFORMATION CONTACT: Mike Kohner, Aerospace Engineer, FAA, 
Rotorcraft Directorate, Rotorcraft Certification Office, 2601 Meacham 
Blvd., Fort Worth, Texas 76137, telephone (817) 222-5447, fax (817) 
222-5783.

SUPPLEMENTARY INFORMATION: A proposal to amend part 39 of the Federal 
Aviation Regulations (14 CFR part 39) to include an airworthiness 
directive (AD) that is applicable to BHTI Model 205A-1 and 205B 
helicopters was published in the Federal Register on June 3, 1999 (64 
FR 29814). That action proposed to require:

--Visually inspecting the spar cap for any crack or disbonding;
--Inspecting the spar cap for any disbonding using a tap hammer;
--Modifying the vertical fin;
--After modifying the vertical fin, inspecting the spar cap for any 
cracks using a dye-penetrant inspection method; and
--Replacing the left-hand spar cap.

    Interested persons have been afforded an opportunity to participate 
in the making of this amendment. No comments were received on the 
proposal or the FAA's determination of the cost to the public. The FAA 
has determined that air safety and the public interest require the 
adoption of the rule as proposed except for minor editorial changes. 
The FAA has determined that these changes will neither increase the 
economic burden on any operator nor increase the scope of the AD.
    The FAA estimates that 150 helicopters of U.S. registry will be 
affected by this AD, that it will take approximately 4 work hours per 
helicopter to accomplish the initial inspections, 0.5 work hour for the 
repetitive inspections, and 180 hours to replace the vertical fin spar 
assembly, and that the average labor rate is $60 per work hour. 
Required parts will cost approximately $300 per helicopter. Based on 
these figures, the total cost impact of the AD on U.S. operators is 
estimated to be $1,705,500 to conduct the initial inspection and one 
repetitive inspection, and replace the vertical vin spar assembly on 
all the fleet.
    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.
    For the reasons discussed above, I certify that this action (1) is 
not a ``significant regulatory action'' under

[[Page 47363]]

Executive Order 12866; (2) is not a ``significant rule'' under DOT 
Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); 
and (3) will not have a significant economic impact, positive or 
negative, on a substantial number of small entities under the criteria 
of the Regulatory Flexibility Act. A final evaluation has been prepared 
for this action and it is contained in the Rules Docket. A copy of it 
may be obtained from the Rules Docket at the location provided under 
the caption ADDRESSES.

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 adding a new airworthiness directive 
to read as follows:

AD 99-18-02-AD  Bell Helicopter, Textron, Inc.: Amendment 39-11268. 
Docket No. 98-SW-72-AD.

    Applicability: Model 205A-1 helicopters with vertical fin spar 
cap, part number (P/N) 212-030-447-001 or -101, installed, and Model 
205B helicopters with vertical fin spar cap, P/N 212-030-447-101, 
installed, certificated in any category.

    Note 1: This AD applies to each helicopter identified in the 
preceding applicability provision, regardless of whether it has been 
otherwise modified, altered, or repaired in the area subject to the 
requirements of this AD. For helicopters 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 (d) 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 as indicated, unless accomplished 
previously.
    To prevent failure of the vertical fin (fin) spar, loss of the 
tail rotor, and subsequent loss of control of the helicopter, 
accomplish the following:
    (a) For Model 205A-1 helicopters with a fin spar cap (spar cap), 
P/N 212-030-447-001, installed, accomplish the following:
    (1) Within 8 hours time-in-service (TIS), modify the vertical 
fin and visually inspect the fin spar for cracks in accordance with 
Part I (A1), paragraphs 1 through 4 of Bell Helicopter Textron, Inc. 
Alert Service Bulletin No. 205-98-70, Revision A, dated September 
21, 1998 (ASB).
    (i) If a crack is discovered on the fin spar, replace the fin 
spar assembly with an airworthy fin spar assembly before further 
flight. Repair any corrosion or disbonding discovered during the 
inspection before further flight.
    (ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an 
equivalent coating to the area where the paint and primer were 
removed. Spray, brush, or wipe on a protective coat of MIL-C-16173, 
Grade 2, or equivalent compound, over the clear lacquer or 
equivalent coating.
    (iii) Install the inspection door, intermediate gearbox cover, 
and tail rotor driveshaft cover.
    (2) After initially modifying and inspecting the fin, inspect 
the fin spar for cracks at intervals not to exceed 8 hours TIS as 
follows:
    (i) Accomplish Part I (A2), paragraphs 1 through 3, of the ASB.
    (ii) If a crack is discovered on the fin spar, replace the fin 
spar cap or spar assembly with airworthy parts before further 
flight. Repair any corrosion or disbonding discovered during the 
inspection before further flight.
    (iii) After inspecting, accomplish Part I (A2), paragraphs 5 and 
6, of the ASB.
    (3) Within 25 hours TIS, inspect and modify the fin assembly as 
follows:
    (i) Accomplish Part II (C1), paragraph 1, of the ASB.
    (ii) Remove the clip, part number (P/N) 212-030-099-091, and 
radius block, P/N 212-030-099-095, if existing. Remove the retainer, 
P/N 212-030-121-037, and sufficient rivets from the bottom row of 
the forward left-hand fin skin to allow trimming of the forward 
left-hand skin along the skin ``cutline'', approximately fin station 
66.31 (see Figure 2 of the ASB).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. If an 
existing edge distance will be less than 1.5 times the diameter of 
the drill or reamed hole, repairs must be performed and must be FAA 
approved before proceeding.
    (iv) Accomplish Part II (C1), paragraphs 3, 4, and 6, in the 
ASB.
    (v) If a crack is discovered on the fin spar, replace the fin 
spar cap or spar assembly with airworthy parts before further 
flight. Repair any corrosion or disbonding discovered during the 
inspection before further flight.
    (vi) Accomplish Part II (C1), paragraphs 10 through 14, of the 
ASB.
    (4) After initially modifying and dye-penetrant inspecting the 
fin spar, inspect the fin spar at intervals not to exceed 300 hours 
TIS as follows:
    (i) Accomplish Part II (C2), paragraphs 1, 2, 3, 4, 5, and 7, of 
the ASB.
    (ii) If a crack is discovered on the fin spar, replace the fin 
spar cap or spar assembly with airworthy parts before further 
flight. Repair any corrosion or disbonding discovered during the 
inspection before further flight.
    (iii) Accomplish Part II (C2), paragraphs 11 through 14, of the 
ASB.
    (5) Within 12 calendar months, remove the left-hand fin spar 
cap, P/N 212-030-447-001. Replace it with an airworthy fin spar cap 
or spar assembly configuration that has been demonstrated to the FAA 
to satisfy the structural fatigue requirements of repeated high-
torque events and is approved by the Manager, Rotorcraft Standards 
Staff.
    (6) Installation of a fin spar cap or assembly that has been 
approved by the Manager, Rotorcraft Standards Staff, constitutes 
terminating action for the requirements of this AD.
    (b) For Model 205A-1 helicopters with a fin spar cap, P/N 212-
030-447-101, installed, accomplish the following:
    (1) Within 8 hours TIS, modify the vertical fin and visually 
inspect the fin spar for cracks in accordance with Part II (A1), 
paragraphs 1 through 5, of the ASB.
    (i) If a crack is discovered on the fin spar, replace the fin 
spar cap or assembly with an airworthy parts before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an 
equivalent coating to the two lower rivet holes and on the surface 
where paint and primer were removed. Spray, brush, or wipe on a 
protective coat of MIL-C-16173, Grade 2 or equivalent compound, over 
the clear lacquer or equivalent coating. To facilitate subsequent 
inspections, do not replace the two lower rivets (see Figure 2 of 
the ASB).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. If an 
existing edge distance will be less than 1.5 times the diameter of 
the drill or reamed hole, repairs must be performed and must be FAA 
approved before proceeding.
    (iv) Fasten the forward left-hand fin skin and the retainer, P/N 
212-030-121-037, to the spar assembly using Hi-Loks and blind rivets 
as specified in Figure 2 of the ASB. Reinstall the clip and radius 
block, if existing, that were removed in accordance with paragraph 2 
of Part II (A1) of the ASB.
    (v) Refinish the reworked area.
    (vi) Install the inspection door, intermediate gearbox cover, 
and tail rotor driveshaft cover.
    (2) After initially modifying and inspecting the fin, inspect 
the fin spar for cracks at intervals not to exceed 8 hours TIS as 
follows:
    (i) Accomplish Part II (A2), paragraphs 1 through 3, of the ASB.
    (ii) If a crack is discovered on the fin spar, replace the fin 
spar cap or assembly with airworthy parts before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (iii) After inspecting, accomplish Part II (A2), paragraphs 5 
and 6, of the ASB.
    (3) Within 25 hours TIS, modify and inspect the vertical fin as 
follows:

[[Page 47364]]

    (i) Accomplish Part II (C1), paragraph 1, of the ASB.
    (ii) Remove the clip, P/N 212-030-099-091, and radius block, P/N 
212-030-099-095, if existing. Remove the retainer, P/N 212-030-121-
037, and sufficient rivets from the bottom row of the forward left-
hand fin skin to allow trimming of the forward left-hand fin skin 
along the skin ``cutline'', approximately fin station 66.31 (see 
Figure 2 of the ASB).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. If an 
existing edge distance will be less than 1.5 times the diameter of 
the drill or reamed hole, repairs must be performed and must be FAA 
approved before proceeding.
    (iv) Accomplish Part II (C1), paragraphs 3, 4, and 6, of the 
ASB.
    (v) If a crack is discovered on the fin spar, replace the fin 
spar cap or assembly with airworthy parts before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (vi) Accomplish Part II (C1), paragraphs 10 through 14, of the 
ASB.
    (4) After initially modifying and dye-penetrant inspecting the 
fin spar, inspect the fin spar at intervals not to exceed 300 hours 
TIS as follows:
    (i) Accomplish Part II (C2), paragraphs 1 through 7, of the ASB.
    (ii) If a crack is discovered on the fin spar, replace the fin 
spar cap or assembly with airworthy parts before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (iii) Accomplish Part II (C2), paragraphs 11 through 14, of the 
ASB.
    (5) Within 25 hours TIS, and thereafter at intervals not to 
exceed 300 hours TIS, inspect the fin spar as follows:
    (i) Accomplish Part II (B), paragraphs 1 through 13, of the ASB.
    (ii) Repair any disbonding discovered during the inspection 
before further flight.
    (6) Within 12 calendar months, remove the left-hand fin spar 
cap, P/N 212-030-447-101. Replace it with an airworthy fin spar cap 
or spar assembly configuration that has been demonstrated to the FAA 
to satisfy the structural fatigue requirements of repeated high-
torque events and is approved by the Manager, Rotorcraft Standards 
Staff.
    (7) Installation of a fin spar that has been approved by the 
Manager, Rotorcraft Standards Staff, that satisfies the requirements 
of paragraph (b)(6) of this AD constitutes terminating action for 
the requirements of this AD.
    (c) For Model 205B helicopters with a fin spar cap, P/N 212-030-
447-101, installed, accomplish the following:
    (1) Within 8 hours TIS, modify the fin and visually inspect the 
fin spar for cracks in accordance with Part I (A1), paragraphs 1 
through 5, of Bell Helicopter Textron, Inc. Alert Service Bulletin 
No. 205B-98-26, Revision A, dated September 21, 1998 (205B ASB).
    (i) If a crack is discovered on the fin spar, replace the fin 
spar cap or assembly with airworthy parts before further flight. 
Repair any corrosion or disbonding discovered during the inspection 
before further flight.
    (ii) After inspecting, apply MIL-PRF-81352 clear lacquer or an 
equivalent coating to the two lower rivet holes and on the surface 
where paint and primer were removed. Spray, brush, or wipe on a 
protective coat of MIL-C-16173, Grade 2, or equivalent compound, 
over the clear lacquer. To facilitate subsequent inspections, do not 
replace the two lower rivets (see Figure 2 of the 205B ASB).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. If an 
existing edge distance will be less than 1.5 times the diameter of 
the drill or reamed hole, repairs must be performed and must be FAA 
approved before proceeding.
    (iv) Fasten the forward left-hand fin skin and the retainer, P/N 
212-030-121-037, to the spar assembly using Hi-Loks and blind rivets 
as specified in Figure 2 of the 205B ASB. Reinstall the clip and 
radius block, if existing, removed in paragraph 2 of Part I (A1) of 
the 205B ASB.
    (v) Install the inspection door, intermediate gearbox cover, and 
tail rotor driveshaft cover.
    (2) After initially modifying and inspecting the fin, inspect 
the fin spar for cracks at intervals not to exceed 8 hours TIS as 
follows:
    (i) Accomplish Part I (A2), paragraphs 1 through 3, of the 205B 
ASB.
    (ii) If a crack is discovered on the spar, replace the fin spar 
cap or assembly with airworthy parts before further flight. Any 
corrosion or disbonding discovered during the inspection must be 
repaired before further flight.
    (iii) After inspecting, accomplish Part I (A2), paragraphs 5 and 
6, of the 205B ASB.
    (3) Within 25 hours TIS, modify and inspect the fin as follows:
    (i) Accomplish Part I (C1), paragraph 1 of the 205B ASB.
    (ii) Remove the clip, P/N 212-030-099-091, and radius block, P/N 
212-030-099-095, if existing. Remove the retainer, P/N 212-030-121-
037, and sufficient rivets from the bottom row of the forward left-
hand fin skin to allow trimming of the forward left-hand fin skin 
along the skin ``cutline'', approximately fin station 66.31 (see 
Figure 2 of the 205B ASB).
    (iii) Before drilling or reaming, inspect all holes in the spar 
cap where rivets were removed for short edge distance. If an 
existing edge distance will be less than 1.5 times the diameter of 
the drill or reamed hole, repairs must be performed and must be FAA 
approved before proceeding.
    (iv) Accomplish Part I (C1), paragraphs 3, 4, and 6, in the 205B 
ASB.
    (v) If a crack is discovered on the spar, replace the fin spar 
cap or assembly with airworthy parts before further flight. Any 
corrosion or disbonding discovered during the inspection must be 
repaired before further flight.
    (vi) Accomplish Part I (C1), paragraphs 10 through 14, of the 
205B ASB.
    (4) After initially modifying and dye-penetrant inspecting the 
fin spar, inspect the fin spar at intervals not to exceed 300 hours 
TIS as follows:
    (i) Accomplish Part I (C2), paragraphs 1, 2, 3, 4, 5, and 7, of 
the 205B ASB.
    (ii) If a crack is discovered on the spar, replace the fin spar 
cap or assembly with airworthy parts before further flight. Any 
corrosion or disbonding discovered during the inspection must be 
repaired before further flight.
    (iii) Accomplish Part I (C2), paragraphs 11 through 14, of the 
205B ASB.
    (5) Within 25 hours TIS, inspect the fin spar at intervals not 
to exceed 300 hours TIS as follows:
    (i) Accomplish Part I (B), paragraphs 1 through 13, of the 205B 
ASB.
    (ii) Any disbonding discovered during the inspection must be 
repaired before further flight.
    (6) Within 12 calendar months, remove the left-hand fin spar 
cap, P/N 212-030-447-101. Replace it with an airworthy fin spar cap 
configuration that has been demonstrated to the FAA to satisfy the 
structural fatigue requirements of repeated high-torque events and 
is approved by the Manager, Rotorcraft Standards Staff.
    (7) Installation of a fin spar that satisfies the above 
requirements and has been approved by the Manager, Rotorcraft 
Standards Staff, constitutes a terminating action for the 
requirements of this AD.
    (d) An alternative method of compliance or adjustment of the 
compliance time that provides an acceptable level of safety may be 
used if approved by the Manager, Rotorcraft Standards Staff, 
Rotorcraft Directorate, FAA. Operators shall submit their requests 
through a FAA Principal Maintenance Inspector, who may concur or 
comment and then send it to the Manager, Rotorcraft Standards Staff.

    Note 2: Information concerning the existence of approved 
alternative methods of compliance with this AD, if any, may be 
obtained from the Rotorcraft Standards Staff.

    (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 helicopter to a location where 
the requirements of this AD can be accomplished.
    (f) The modification of the vertical fin, the visual and dye-
penetrant inspections, and any necessary repairs shall be done in 
accordance with Bell Helicopter Textron, Inc. Alert Service Bulletin 
No. 205-98-70, Revision A, or No. 205B-98-26, Revision A, both dated 
September 21, 1998, 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. Copies may be obtained from 
Bell Helicopter Textron, Inc., P.O. Box 482, Fort Worth, Texas 
76101, telephone (817) 280-3391, fax (817) 280-6466. Copies may be 
inspected at the FAA, Office of the Regional Counsel, Southwest 
Region, 2601 Meacham Blvd., Room 663, Fort Worth, Texas; or at the 
Office of the Federal Register, 800 North Capitol Street, NW., suite 
700, Washington, DC.
    (g) This amendment becomes effective on October 5, 1999.


[[Page 47365]]


    Issued in Fort Worth, Texas, on August 18, 1999.
Henry A. Armstrong,
Manager, Rotorcraft Directorate, Aircraft Certification Service.
[FR Doc. 99-22077 Filed 8-30-99; 8:45 am]
BILLING CODE 4910-13-U