N220FFFreeman Lloyd C SUPER KOALA · 2008

On July 6, 2019, at 1045 central daylight time, an experimental amateur-built Freeman Super Koala, N220FF, experienced a hard landing during a return to Mercer County Regional Airport (HZE), Hazen, North Dakota, following a loss of aileron control. The commercial pilot was uninjured and the airplane was substantially damaged. The airplane was registered to and operated by the airplane owner under Title 14 Code of Federal Regulations Part 91 as a maintenance test flight that was not operating on a flight plan. Day visual meteorological conditions prevailed at the time of the accident. The local flight originated from HZE.

The pilot reported that the airplane had undergone reassembly of its wings and flight control rigging prior to the flight. On the day of the accident, he performed the fourth test flight of the airplane. He reported the airplane was having issues with the ailerons being fully functional once in flight. The pilot and the airplane owner were attempting to diagnose and fix the issue. The pilot preflighted the airplane, taxied out, performed a run-up, and confirmed the controls were free and correct. During the takeoff form runway 14, the airplane "quickly" became airborne and about 15 ft above the ground began to roll to the left. After applying full right aileron, the airplane continued to roll left and descend, which led to a left wing-low impact with the ground roughly 10-20 ft from the runway. The airplane's left wing spar, bottom fuselage, cowling, engine, landing gear, and firewall were substantially damaged.

The Federal Aviation Administration (FAA) inspector from the Fargo, North Dakota, Flight Standards District Office reported the airplane was purchased by the current owner from an estate. The airplane was disassembled and transported via trailer to Hazen, North Dakota. The airplane owner along with a FAA certificated mechanic assembled the airplane and they told the inspector they had issues with the aileron cable tensions. The airplane owner reported that he called the kit manufacturer but was unable to get the information he needed. After several attempts to properly adjust the aileron cable tensions, they determined that test flights would be needed. Post-accident inspection of the airplane revealed improper rigging of the ailerons and improper cable tensions. Inspection of the airplane maintenance logbook revealed the airplane was not properly signed off for return to service after maintenance.

On August 24, 2010, about 1110 eastern daylight time, an experimental amateur-built Freeman Super Koala airplane, N220FF, owned and piloted by a commercial pilot, was substantially damaged when it impacted terrain during a forced landing following a loss of engine power during cruise flight near Traverse City, Michigan. Visual meteorological conditions prevailed at the time of the accident. The personal flight was being conducted under the provisions of Title 14 Code of Federal Regulations Part 91 without a flight plan. The pilot sustained minor injuries. The local flight originated from the Cherry Capital Airport, near Traverse City, Michigan, about 1050.

The pilot reported that during the climb he reduced power to 6,000 rpm about three to four minutes after takeoff. The pilot switched the fuel tank selector from the main tank to the auxiliary tank. The engine’s rpms subsequently dropped from 6,000 to 2,000 rpm. He switched the fuel tank selector back to the main tank and the engine’s rpms did not increase. He applied the choke and no increase in engine rpms was observed. According to the pilot, he attempted to execute a forced landing to the “only open space available.” The area which the pilot picked to perform the forced landing had rising terrain. He said that the left wing dropped and the airplane turned about 55 degrees to the left before impact. The pilot stated that the airplane Hobbs meter accumulated 0.4 hour since the start of the flight.

According to the pilot, the airplane had accumulated 49.5 hours of total airframe time at the time of the accident. The airplane’s airworthiness was maintained by the owner/pilot under a conditional maintenance program and the last conditional inspection was performed on February 18, 2010. The airplane was powered by a two cylinder, two-stroke, 50-horsepower Rotax 503 UL engine with serial number 360-5697. The engine was sold to the airplane's kit manufacturer in March of 1986 and according to the pilot, it had not been overhauled.

A Federal Aviation Administration inspector examined the wreckage. Engine control continuity was established. The engine’s fuel filters were clean. The number one cylinder exhaust port exhibited an accumulation of carbon. The number one cylinder’s spark plug could be loosened by hand and it exhibited a fouled appearance when it was removed.

The engine’s maintenance manual included an itemized maintenance plan that listed a "general overhaul of the engine" as planned and necessary maintenance. A supplemental note indicated that the overhaul is to be carried out every 5 years or every 300 hours, whichever comes first. The maintenance manual further indicated that the spark plugs are to be tightened on a cold engine to 240-inch pounds of torque.