Appendix A A-2 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
FLIGHT CONTROLS PROPERLY RIGGED/PROPER TENSION
INSPECT ALL CONTROL STOPS FOR SECURITY
TRIM CONTROL PROPERLY RIGGED
TRIM CONTROL SURFACES/HINGES/ROD END BEARINGS SERV.
FRAYED CABLES OR CRACKED/FROZEN/RATCHETING
PULLEYS
SKIN PANELS DELAMINATE/VOIDS (COIN TEST)
POPPED RIVETS/CRACKED/DEFORMED SKIN
FABRIC/RIB STITCHING/TAPE CONDITION
LUBRICATION
WING ATTACH POINTS
FLYING/LANDING WIRES/STRUTS FOR SECURITY
CORROSION
FOR ULTRALIGHT CHECK
FLIGHT CONTROL BOLTS/PINS FOR SAFETY AND
CONDITION
WING/STRUT/CABLE ATTACHMENTS AND HARDWARE FOR
SAFETY AND CONDITION
Appendix A A-3 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
FUEL SYSTEM:
CORROSION
FUEL LINES FOR CHAFING/LEAKS/SECURITY/CONDITION
SUMP ALL FUEL TANKS FOR WATER OR DEBRIS
FUEL CAPS FOR SECURITY
FUEL PLACARD
FUEL VALVE/CROSS FEED/FOR OPERATION AND SECURITY
CLEAN FUEL FILTERS/GASCOLATOR/FLUSH SYSTEM
INSPECT FUEL TANK VENT SYSTEM
LANDING GEAR:
INSPECT STRUTS/TORQUE LINKS FOR ATTACHMENT
INSPECT STRUTS FOR PROPER EXTENSION
INSPECT FOR HYDRAULIC LEAKS
CHECK ALL BUSHINGS FOR WEAR/FREE PLAY
CHECK LUBRICATION
INSPECT WHEELS FOR ALIGNMENT
WHEEL/TIRES FOR CRACKS AND SERVICEABILITY
WHEEL BEARINGS FOR LUBRICATION
Appendix A A-4 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
INSPECT FOR CORROSION
INSPECT NOSE GEAR FOR CRACKS AND TRAVEL
INSPECT TAIL WHEEL FOR CRACKS AND TRAVEL
PERFORM GEAR RETRACTION TEST/CHECK INDICATOR LIGHTS
EMERGENCY GEAR RETRACTION SYSTEM
CHECK TIRE PRESSURE
BRAKE LINING WITHIN LIMITS
BRAKE DISKS FOR CRACKS, WEAR, AND DEFORMITY
BRAKE HYDRAULIC LINES FOR LEAKS AND SECURITY
FUSELAGE:
REMOVE INSPECTION PLATES AND PANELS
INSPECT BULKHEADS AND STRINGERS FOR POPPED RIVETS
AND CRACKED SKIN
INSPECT FOR DELAMINATED SKIN/VOIDS (COIN TEST)
INSPECT THE SECURITY OF ALL INTERNAL LINES
INSPECT WINDOWS/CANOPY FOR CRACKS AND FIT
INSPECT DOOR OR CANOPY LATCHING MECHANISM
INSPECT FIRE WALL FOR DISTORTION AND CRACKS
INSPECT RUDDER PEDALS AND BRAKES FOR OPERATION
AND SECURITY
Appendix A A-5 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
INSPECT BEHIND FIREWALL FOR LOOSE WIRES AND
CHAFING LINES
CHECK CONTROL STICK/YOKE FOR FREEDOM OF
MOVEMENT
CHECK FLAP CONTROL OPERATION
CHECK CABLE AND PULLEYS FOR ATTACHMENT AND
OPERATION
PERFORM FLOODLIGHT CARBON MONOXIDE TEST
ENSURE THE COCKPIT INSTRUMENTS ARE PROPERLY MARKED
INSPECT INSTRUMENTS, LINES, FOR SECURITY
CHECK/CLEAN/REPLACE INSTRUMENT FILTER
INSPECT COCKPIT FRESH AIR VENTS/HEATER VENTS FOR
OPERATION AND SECURITY
INSPECT SEATS, SEATBELTS/SHOULDER HARNESS FOR
SECURITY AND ATTACHMENT
CORROSION
CHECK BALLISTIC PARACHUTE INSTALLATION PER
MANUFACTURER
RECOMMENDATIONS
EMPENNAGE/CANARD
REMOVE INSPECTION PLATES AND FAIRINGS
INSPECT CANARD ATTACH POINTS FOR SECURITY
INSPECT VERTICAL FIN ATTACH POINTS
Appendix A A-6 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
INSPECT ELEVATOR/STABILIZER ATTACH POINTS
INSPECT HINGES/TRIM TABS/ROD ENDS FOR ATTACHMENT
AND FREE PLAY (SLOP)
INSPECT EMPENNAGE/CANARD SKIN FOR
DAMAGE/CORROSION
INSPECT ALL CONTROL CABLES, HINGES AND PULLEYS
INSPECT ALL CONTROL STOPS FOR ULTRALIGHT:
CHECK ALL ATTACHMENT POINTS AND CONTROL FOR
SAFETY CONDITION
ENGINE:
PERFORM COMPRESSION TEST—CYLINDER #1 ___ #2 ___ #3 ___ #4 ___ #5 ___ #6 ___
CHANGE OIL AND FILTER (CHECK FOR METAL)
INSPECT IGNITION HARNESS FOR CONDITION AND
CONTINUITY
CHECK IGNITION LEAD INSULATORS (CIGARETTES) FOR
CONDITION/CRACKS
CLEAN AND GAP SPARK PLUGS
CHECK MAGNETO TIMING/POINTS/OIL SEAL/DISTRIBUTOR
INSPECT ENGINE MOUNT/BUSHINGS
INSPECT ENGINE MOUNT ATTACHMENT BOLT TORQUE
INSPECT ALTERNATOR/GENERATOR ATTACHMENT
CHECK ALTERNATOR/GENERATOR BELT CONDITION
INSPECT CYLINDERS FOR CRACKS/BROKEN FINS/EXHAUST STAINS
INSPECT ENGINE BAFFLES FOR CRACKS/CONDITION
Appendix A A-7 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
CHECK FOR OIL LEAKS INSPECT VACUUM PUMP AND LINES
INSPECT OIL VENT LINES
INSPECT ALL CABIN HEAT/CARB HEAT/DEFROSTER DUCTS
FOR CONDITION
INSPECT CARBURETOR FOR SECURITY & CLEAN INLET SCREEN
INSPECT INTAKE HOSES/SEALS FOR SECURITY/LEAKS
INSPECT THROTTLE/MIXTURE/CARB HEAT/CONTROL FOR
PROPER TRAVEL AND SECURITY
INSPECT CARB HEAT AIR BOX FOR CRACKS/OPERATION
INSPECT CONDITION OF FLEXIBLE FUEL AND OIL LINES
INSPECT OIL COOLER FOR LEAKS AND CONDITION
CHECK EXHAUST SYSTEM FOR ATTACHMENT & CONDITION
CHECK MUFFLER/INTERNAL BAFFLE/FOR SECURITY
CHECK EXHAUST PIPES/FLANGES FOR SECURITY &
ATTACHMENT
REPACK EXHAUST GASKETS AS REQUIRED
CHECK COWLING FOR CRACKS AND SECURITY FOR ULTRALIGHT:
CHECK CARB BOOTS ON 2-CYCLE ENGINES FOR CRACKS
CHECK SAFETIES ON EXHAUST SPRINGS PERFORM 2-CYCLE COMPRESSION TEST TO CHECK SEALS
ENSURE SPARK PLUG CAPS ARE SAFETIED ON INVERTED
ENGINES
PROPELLER:
CHECK SPINNER AND BACK PLATE FOR CRACKS
Appendix A A-8 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
INSPECT FOR CRACKS/STONE DAMAGE/NICKS
CHECK FOR DELAMINATION (WOOD/COMPOSITE BLADES)
CHECK PROP BOLTS TORQUE/SAFETY WIRE
CHECK FOR OIL LEAKS (CRANKCASE NOSE SEAL)
GREASE LEAKS (CONSTANT SPEED PROP)
CHECK PROPELLER GOVERNOR FOR LEAKS AND
OPERATION
CHECK PROP TRACK
CHECK PROP BALANCE (WOOD PROP)
ELECTRICAL
SPARE FUSES AVAILABLE
BATTERY SERVICED AND FREE FROM CORROSION
BATTERY BOX FREE FROM CORROSION
ELT BATTERY FREE FROM CORROSION AND CURRENT
BATTERY
CHECK LANDING LIGHT OPERATION
CHECK POSITION LIGHTS OPERATION
CHECK ANTI COLLISION LIGHT FOR OPERATION
INSPECT ALL ANTENNA MOUNTS AND WIRING FOR
SECURITY
CHECK ALL GROUNDING WIRES (ENGINE TO AIRFRAME, WING TO AILERON/FLAP, ETC.)
INSPECT RADIOS/LEADS/WIRES FOR ATTACHMENT &
SECURITY
Appendix A A-9 S = SATISFACTORY U = UNSATISFACTORY (correct all unsatisfactory items prior to flight) Builder/Inspector
S U S U
INSPECT CIRCUIT BREAKERS/FUSES PANELS FOR
CONDITION
OPERATIONAL INSPECTION:
VISUAL INSPECTION OF THE ENGINE/PROPELLER
ALL INSPECTION PANELS AND FAIRINGS SECURE
PERSONNEL WITH FIRE BOTTLE STANDING BY
BRAKE SYSTEM CHECK
PROPER FUEL IN TANKS
ENGINE START PROCEDURES
OIL PRESSURE/OIL TEMPERATURE WITHIN LIMITS
VACUUM GAUGE CHECK
MAGNETO CHECK/HOT MAG CHECK
IDLE RPM/MIXTURE CHECK
STATIC RPM CHECK
ELECTRICAL SYSTEM CHECK
COOL DOWN PERIOD/ENGINE SHUT DOWN
PERFORM OIL, HYDRAULIC, AND FUEL LEAK CHECK PAPERWORK:
AIRWORTHINESS DIRECTIVES
RECORD FINDINGS AND SIGN OFF INSPECTION
MAINTENANCE IN AIRCRAFT LOGBOOKS
Appendix B B-1 APPENDIX B. SOURCES FOR ACCIDENT/INCIDENT INFORMATION B.1 Accident/incident reports for all U.S.-registered make and model aircraft are available from the following sources:
B.1.1 Federal Aviation Administration (FAA):
https://www.faa.gov/data_research/accident_incident.
B.1.2 National Transportation Safety Board (NTSB):
https://www.ntsb.gov/investigations/AccidentReports/Pages/Reports.aspx.
Appendix C C-1 APPENDIX C. ADDITIONAL REFERENCES ON FLIGHT TESTING The following references comprise selected additional information sources on flight testing and first flight experiences for amateur-built aircraft and ultralight vehicles. This list of informational material may help amateur builders in preparing the FLIGHT TEST PLAN for their aircraft and ultralights.
Experimental Aircraft Association (EAA) publications are available in the EAA archives, a benefit available to EAA members. Non-members can obtain copies, for a fee, by calling 1-800-564-6322.
Some of these publications are out of print but may be available on auction sites such as eBay.
C.1 Industry Publications, Amateur-Built Aircraft:
• Askue, Vaughan, Flight Testing Homebuilt Aircraft, (Ames, IA: State University Press, 1992).
• Ariosto, James, “A Two Minute Test-Hop Reveals All Wrongs,” Sport Aviation, (May 1970), pp. 29–30.
• Bingelis, Antoni, “A Report on the 1973 Oshkosh Safety and Courtesy Inspections,” Sport Aviation, (November 1973), pp. 35–37.
• ____ “After the First Test Flight,” Sport Aviation, (April 1988), pp. 27–30.
• ____ “Flight Testing Homebuilts-Stage One: Making Preparations for Flight Testing,” Sport Aviation, (January 1989), pp. 27–30.
• ____ “Flight Testing Homebuilts-Stage Two: Making the Initial Flight Test,” Sport Aviation, (February 1989), pp. 27–30.
• ____ “Flight Testing Homebuilts-Stage Three: Expanding the Flight Envelope,” Sport Aviation, (March 1989), pp. 28–31, 66.
• Donofrio, P. R., “Checkmate,” Sport Aviation, (June 1978), pp. 30–31.
• Dwiggins, Don, “Flight Testing Your Homebuilt,” Homebuilt Aircraft, (July 1985), pp. 40–43.
• ____ “Flight Testing Your Homebuilt,” Plane and Pilot, (Annual, 1974), pp. 56–61.
• Enman, Ann, “The Moment of Truth! The Test Flight,” Air Progress 1989 Guide to Sport Aircraft Kits, pp. 16–19.
• Experimental Aircraft Association, The EAA Flight Test Manual, (Oshkosh WI:
Experimental Aircraft Association, Inc., 2018).
• Experimental Aircraft Association, Pilot Reports and Flight Testing, V. 1, pg. 72 (1977). Selected first flight reports and flight testing procedures.
• Friedman, Peter, “High Tech-First flight,” Sport Pilot, (February 1989), pp. 16, 17, 72, 73.
Appendix C C-2
• Goyar, Norman, “Free Insurance and How to Get It,” Sport Pilot, j. 5, No. 3 (1989), pp. 44–49.
• Heintz, Chris, “The First Flight of Your Aircraft,” EAA Light Plane World, (May 1986), pp. 7–9.
• ____ “Performance Testing Your Aircraft,” EAA Light Plane World, (July 1986), pp. 13–15.
• Hurt, H. H., Jr., Aerodynamics for Naval Aviators, (California: University of Southern California, 1960 [revised 1965]). NAVAIR 00-80T-80. Issued by the Office of the Chief of Naval Operations, Aviation Training Division.
• Jacquemin, G., “Flight-testing for the Amateur,” Sport Aviation, (April 1965), pg. 4.
• Kerley, Jim, “Thoughts on Test Flying,” Sport Aviation, (March 1970), pp. 34–35.
• Ladd, Robert W., “The Test Flight of Chihuahua,” Sport Aviation, (February 1968), pg. 4.
• Macq, Harvey, “Test Flight,” Sport Aviation, (March 1960), pg. 3.
• Mason, Sammy, Stalls, Spins, and Safety, (New York: Macmillan Publishing Company, 1985).
• Mitchell, C.G.B., “Design of the ‘Kittiwake’ Family of Light Aircraft,” (Part 2) Sport Aviation, (March 1969), pp. 36–37.
• Rhodes, Mike, “First Flight—Trial by Fire,” (Part 1) Sport Aviation, (August 1988), pp. 26, 27, 29.
• Smith, Hubert, Performance Flight Testing, (Blue Ridge Summit: Tab Books, Inc.
[Modern Aviation Series], 1982), pg. 131.
• Sport Aviation, “Pointers on Test Flying Complied by Chapter 32, St. Louis, MO,” Sport Aviation, (December 1960), pg. 3.
• Sport Planes, “The Sacramento Seaplanes,” Sport Planes, (Fall 1970), pp. 16–27.
• Taylor, M. B., “Testing your Homebuilt,” Sport Aviation, (January 1977), pg. 24–27.
• Tausworthe, Jim, “The Brotherhood of Flight,” Sport Aviation, (August 1969), pg. 22.
• Thorp, J. W., “Structural Flight Testing,” Sport Aviation, (November 1961), pg. 2.
• Wendt, H. O., “Designing, Building, and Flight Testing of the Wendt Wh-1 Traveler,” Sport Aviation, (March 1973), pg. 10–15.
• White, E. J., “Super Coot—The Fisherman’s Homebuilt,” Homebuilt Aircraft, (September 5, 1981), pg. 1821.
• Wood, Karl D., Technical Aerodynamics, (New York: McGraw Hill, 1947).
Appendix C C-3 C.2 Industry Publications, Ultralights:
• Brooke, Rob, “Greatest Peril,” Ultralight Flying, (September 1993), pp. 42–43.
• Cannon, Mike, “Learning to Fly—Again,” Ultralight Flying, (June 1988), pg. 5.
• ____ “Keeping Cool in the Summer Time,” Ultralight Flying, (August 1988), pp. 16–17.
• Cartier, Kerry, “Power Failure on Take-off,” Ultralight Flying, (January 1988), pg. 25.
• Chapman, John, and Smith, Clark, “Preparing for the In-Flight Emergency,” Ultralight Flying, (March 1989), pg. 32.
• Demeter, Dennis, “Risk Management,” Ultralight Flying, (July 1993), pp. 48–49.
• ____ “Don’t Forget the Pre-flight,” Ultralight Flying, (May 1993), pp. 70–71.
• Gunnarson, Tom, “Getting into Ultralight Float Flying,” Ultralight Flying, (April 1989), pp. 27–29.
• Johnson, Don, “Getting the Most out of Flight Reviews,” Ultralight Flying, (March 1989), pp. 20–23.
• Loveman, Dave, “Problem-Solving the Cayuna 430R,” Ultralight Flying, (June 1988), pp. 24–25.
• Pagen, Dennis, “‘G’ forces and your Ultralight,” Ultralight Flying, (August 1989), pg. 37.
• ____ “Weight and Speed,” Ultralight Flying, (May 1989), pp. 20–21.
• Peghiny, Tom, “Effects of Sunlight on Polyester Sail Cloth,” Ultralight Foundation, Volume 2, Number 1, pp. 49–50, (1986).
C.3 Government Publications:
C.3.1 FAA Advisory Circulars (AC). Current editions of ACs are available at https://www.faa.gov/regulations_policies/advisory_circulars.
• AC 20-35, Tiedown Sense.
• AC 20-37, Aircraft Propeller Maintenance.
• AC 20-42, Hand Fire Extinguishers for Use in Aircraft.
• AC 20-105, Reciprocating Engine Power-Loss Accident Prevention and Trend Monitoring.
• AC 20-125, Water in Aviation Fuels.
• AC 23-8, Flight Test Guide for Certification of Part 23 Airplanes.
• AC 23-16, Powerplant Guide for Certification of Part 23 Airplanes and Airships.