N385WRPiper PA-32R-300 · 1976

On May 8, 2008, approximately 1530 central daylight time, a single-engine, Piper PA-32R-300 airplane, N385WR, was substantially damaged upon impact with terrain following a loss of engine power while in cruise flight near Emporia, Kansas. The private pilot, sole occupant on board, received minor injures. The airplane was registered to TNJ Trucking, Inc. of Estherville, Iowa and operated by the pilot. Visual meteorological conditions prevailed for the 14 Code of Federal Regulations Part 91 flight.

The flight departed Tradewinds airport (KTDW), Amarillo, Texas about 13:45 for the 330-nautical mile cross country flight. In a written statement, the pilot reported after he passed Cottonwood, Kansas (and less than 30 miles from Emporia) he turned on the fuel boost pump, and switched fuel tanks. About 10 miles from Emporia and at an altitude of 3,500 feet the pilot the "plane got quiet." The pilot cycled the magnetos and fuel tank selector "once or twice." Unable to restart the engine, the pilot conducted a forced landing in a field, about 10 miles west of Emporia.

The Federal Aviation Administration (FAA) inspector, who responded to the accident site, reported that the aircraft received structural damage during the forced landing. The FAA inspector also noted that fuel was present in the airplane's fuel tanks. A follow-on inspection of the airplane found no mechanical or electrical problem with the engine. However, the left inboard fuel tank appeared to have large sections of "sloshing" compound peeling from the tanks walls blocking the fuel tank outlet.

A review of maintenance records revealed that the left inboard fuel tank was treated with Randolph 802 (sloshing compound) sealer in February 1996. At the time of the application, the procedure was acceptable per the Piper Service Manual.

The review also noted that Piper Service Bulletin 251C, dated May 16, 2005, no longer recognizes Randolph 802 as an approved sealer, and that the sloshing procedure should be removed from all Piper Service Manuals. Additionally, the service bulletin did not contain additional instructions with regards to tanks that had been previously repaired using this procedure.