# NTSB CEN09LA494: Crisman Flightstar Iisc, N5008E, Malta, IL, July 24, 2009 - Type: NTSB accident investigation - Classification: Accident · No injuries · Limited investigation · Final report - Date: July 23, 2009, 19:00 local (Jul 24, 2009, 00:00 UTC) - Place: Malta, IL - Coordinates: 41.929103, -88.859909 (estimated) - Nearby events: https://openairdocs.org/map.md?lat=41.9291&lon=-88.8599&mi=10 - Phase of flight: [Enroute](https://openairdocs.org/ntsb-phases/400) (OpenAirDocs' grouping) - Defining event: [Enroute-climb to cruise: Powerplant sys/comp malf/fail](https://openairdocs.org/ntsb-events/340) - Highest injury: No injuries - Injuries: 2 uninjured - Status: Completed, report August 12, 2010 - Report: Approved by Office Director - NTSB office: Central Region - Parties: Federal Aviation Administration - NTSB case key (mKey): 74450 - NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=CEN09LA494 - NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/74450/pdf - NTSB docket: https://data.ntsb.gov/Docket?ProjectID=74450 - Page: https://openairdocs.org/ntsb/CEN09LA494 ## Probable cause The loss of engine power due to the separation of the flywheel, resulting in a high-cycle fatigue fracture of the crankshaft following takeoff, which resulted in a forced landing on an agricultural field. ## Findings NTSB's coded findings; those marked are part of the probable cause. - [Engine (reciprocating): recip engine power section](https://openairdocs.org/ntsb-findings/01058520): Aircraft › Aircraft power plant · Fatigue/wear/corrosion (probable cause); cases with it: [Crisman Harry FLIGHTSTAR IISC, 1 case](https://openairdocs.org/ntsb-findings/01058520/cases.md?model=05901UK), [All aircraft, 233 cases](https://openairdocs.org/ntsb-findings/01058520/cases.md) - [Terrain: rough terrain](https://openairdocs.org/ntsb-findings/03021015): Environmental issues › Physical environment · Contributed to outcome; cases with it: [Crisman Harry FLIGHTSTAR IISC, 1 case](https://openairdocs.org/ntsb-findings/03021015/cases.md?model=05901UK), [All aircraft, 442 cases](https://openairdocs.org/ntsb-findings/03021015/cases.md) ## Sequence of events The events NTSB coded, in order, by phase of flight. The defining event best describes what happened. - [Enroute-climb to cruise: Powerplant sys/comp malf/fail](https://openairdocs.org/ntsb-events/340) (defining event); cases with it: [Crisman Harry FLIGHTSTAR IISC, 1 case](https://openairdocs.org/ntsb-events/340/sequence.md?model=05901UK), [All aircraft, 820 cases](https://openairdocs.org/ntsb-events/340/sequence.md) - [Enroute-climb to cruise: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341); cases with it: [Crisman Harry FLIGHTSTAR IISC, 1 case](https://openairdocs.org/ntsb-events/341/sequence.md?model=05901UK), [All aircraft, 3,820 cases](https://openairdocs.org/ntsb-events/341/sequence.md) - [Emergency descent: Off-field or emergency landing](https://openairdocs.org/ntsb-events/440); cases with it: [Crisman Harry FLIGHTSTAR IISC, 1 case](https://openairdocs.org/ntsb-events/440/sequence.md?model=05901UK), [All aircraft, 3,365 cases](https://openairdocs.org/ntsb-events/440/sequence.md) ## Analysis The experimental light sport airplane experienced a total loss of engine power after takeoff. The pilot then performed a forced landing to a corn field. Examination of the airplane revealed that the crankshaft had fractured near the engine flywheel due to the separation of the flywheel. The separated flywheel precluded further rotation of the crankshaft. Metallurgical examination of the flywheel separation revealed a high-cycle fatigue fracture of the crankshaft. ## Factual narrative On July 23, 2009, at 1900 central daylight time, an experimental light sport Crisman Flightstar IISC, N5008E, experienced a total loss of engine power after takeoff. The airplane sustained substantial damage on impact with terrain during a forced landing on a field near Malta, Illinois. Visual meteorological conditions prevailed at the time of the accident. The sport pilot and passenger were uninjured. The 14 CFR Part 91 personal flight was originating at the time of the accident. The pilot departed from a private grass air strip when the engine experienced a total loss of engine power about 150-200 feet above ground level. The pilot then performed a forced landing on a corn field. The airplane sustained structural damage to both wings and the fuselage. The airplane was powered by a Hirth 2704, serial number 895034, engine that accumulated a reported total time of 127 hours. The pilot stated that the engine was purchased in April 2009 from the previous owner. At the time of purchase, the engine had been broken-in and accumulated two hours of operation. The pilot stated that he had been contacted by the Hirth distributer for the replacement of the flywheel to preclude crankshaft failure. The pilot then obtained and installed a replacement flywheel from the Hirth distributer and then repeated the engine break-in for an additional two hours. According to the Hirth distributer, the engine was subject to a replacement of the flywheel to preclude crankshaft failure. If the engine had accumulated zero hours of time, then only the flywheel had to be replaced, which could be performed by Hirth or outside maintenance personnel; however, if the engine had been run, then the engine would have to be sent to Hirth so that non destructive testing of the crankshaft could also be performed. The flywheels were being replaced due to a manufactured imbalance in the flywheel. External inspection of the engine revealed that the starter ring(flywheel) assembly had separated. The starter ring (flywheel) assembly was contained within the crankshaft housing and was resting against the internal portion of the housing and the crankshaft, which had precluded rotation of the crankshaft. Examination of the starter ring (flywheel) and crankshaft revealed that the crankshaft was fractured along a left-handed helical plane, 45 degrees to the crankshaft’s longitudinal axis immediately forward of the starter ring (flywheel). The orientation and appearance of the fracture surface was consistent with torsion-driven fatigue crack across 86 percent of the fracture with the remaining fracture consistent with overstress or unknown due to subsequent damage. Crack arrest marks were traced back to a single initiation site. When viewed from the side, wear marks were observed beginning at this location where the shaft engaged the taper on the starter ring (flywheel). ## Aircraft - Registration: [N5008E](https://openairdocs.org/deregistered/N5008E-2013-04-05), registration cancelled 2013-04-05, S/N 315, built 2001 (OpenAirDocs) - Reported make and model: Crisman Flightstar IISC - Registry model: [Crisman Harry FLIGHTSTAR IISC](https://openairdocs.org/model/crisman-harry-flightstar-iisc) (registry code 05901UK) (OpenAirDocs) - Registry engine: [Hirth 2704](https://openairdocs.org/engine/hirth-2704) (registry code 33704, 2 cycle) (OpenAirDocs) - Category: Airplane - Serial number: 315 - Airframe hours: 315 - Engines: Hirth 2704 53 horsepower reciprocating - Damage: Substantial damage - Flight: Personal, Part 91 - Operator: Pilot - Registered owner: Pilot - Airworthiness certificate: Special, Experimental light sport (Special) - Last inspection: Annual, December 13, 2008 - Departed: Malta, IL - Destination: Malta, IL - Airport: Private ## Flight crew As NTSB recorded them. NTSB leaves out names. - Pilot; age 57; injuries: none; sport pilot; airplane ratings: single-engine land; medical: sport pilot; last flight review August 16, 2008; seat: left; flight hours: 152 in this make and model ## Weather - Conditions: Visual (VMC), Day - Visibility: 10 statute miles - Lowest ceiling: none - Temperature: 70 °F ## FAA reports on this event (1) The FAA's own accident and incident reports, matched to the aircraft by N-number and date (OpenAirDocs). - [Accident 20090723017719A](https://openairdocs.org/incident/20090723017719A), Jul 23, 2009: Amtr FLIGHTSTARII, Malta, IL, Substantial damage. On July 23, 2009 at 1900 gmt with visual meteorological conditions, an experimental light sport aircraft, a crisman harry, model flightstar ii, N5008E,… ## Docket (2 files) The files NTSB released with the investigation on May 26, 2010, on NTSB's docket system: https://data.ntsb.gov/Docket?ProjectID=74450. 1.5 MB in all. - Pilot/Operator Aircraft Accident Report, NTSB Form 6120.1 (item 1, .PDF, 503 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40327997&FileExtension=.PDF&FileName=Pilot%2FOperator%20Aircraft%20Accident%20Report,%20NTSB%20Form%206120.1-Master.PDF - Materials Laboratory 15 - Factual Report 10-016 (item 2, .PDF, 1.0 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40325822&FileExtension=.PDF&FileName=Materials%20Laboratory%2015%20-%20Factual%20Report%2010-016-Master.PDF From the NTSB's public API. Aircraft are matched to registry aircraft by N-number and event date, checked against the reported serial number, make and model; the registry's history has gaps, so older matches can be wrong. Compare the reported make and model. --- OpenAirDocs.org is an independent research project of [Contrail Labs](https://contraillabs.com/). It is not affiliated with the FAA or the NTSB. Source documents are U.S. government works in the public domain.