# NTSB CEN14LA307: Rotorway Exec 162F, N6828D, Mt. Comfort, IN, June 21, 2014

- Type: NTSB accident investigation
- Classification: Accident · No injuries · Limited investigation · Final report
- Date: June 21, 2014, 10:30 local (14:30 UTC)
- Place: Mt. Comfort, IN
- Coordinates: 39.85889, -85.909164
- Nearby events: https://openairdocs.org/map.md?lat=39.8589&lon=-85.9092&mi=10
- Phase of flight: [Landing](https://openairdocs.org/ntsb-phases/550) (OpenAirDocs' grouping)
- Defining event: [Landing-flare/touchdown: Roll over](https://openairdocs.org/ntsb-events/097)
- Highest injury: No injuries
- Injuries: 2 uninjured
- Status: Completed, report December 15, 2014
- Report: Approved by Office Director
- NTSB office: Central Region
- Parties: Federal Aviation Administration
- NTSB case key (mKey): 89511
- NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=CEN14LA307
- NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/89511/pdf
- NTSB docket: https://data.ntsb.gov/Docket?ProjectID=89511
- Page: https://openairdocs.org/ntsb/CEN14LA307

## Probable cause

The pilot’s installation of an unauthorized main rotor belt and his subsequent failure to properly inspect the belt, which resulted in inadequate belt tension, the belt’s failure, and the subsequent loss of engine power.

## Findings

NTSB's coded findings; those marked are part of the probable cause.

- [Main rotor drive](https://openairdocs.org/ntsb-findings/01046300): Aircraft › Aircraft propeller/rotor · Failure (probable cause); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-findings/01046300/cases.md?model=05608IJ), [All aircraft, 15 cases](https://openairdocs.org/ntsb-findings/01046300/cases.md)
- [Maintenance/inspections](https://openairdocs.org/ntsb-findings/01010500): Aircraft › Aircraft handling/service · Incorrect service/maintenance (probable cause); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-findings/01010500/cases.md?model=05608IJ), [All aircraft, 103 cases](https://openairdocs.org/ntsb-findings/01010500/cases.md)
- [Maintenance: installation](https://openairdocs.org/ntsb-findings/02062035): Personnel issues › Task performance · Pilot (probable cause); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-findings/02062035/cases.md?model=05608IJ), [All aircraft, 371 cases](https://openairdocs.org/ntsb-findings/02062035/cases.md)
- [Terrain: wet/muddy terrain](https://openairdocs.org/ntsb-findings/03021035): Environmental issues › Physical environment · Contributed to outcome; cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-findings/03021035/cases.md?model=05608IJ), [All aircraft, 110 cases](https://openairdocs.org/ntsb-findings/03021035/cases.md)

## Sequence of events

The events NTSB coded, in order, by phase of flight. The defining event best describes what happened.

- [Landing-flare/touchdown: Abnormal runway contact](https://openairdocs.org/ntsb-events/090); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-events/090/sequence.md?model=05608IJ), [All aircraft, 1,506 cases](https://openairdocs.org/ntsb-events/090/sequence.md)
- [Landing-flare/touchdown: Roll over](https://openairdocs.org/ntsb-events/097) (defining event); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-events/097/sequence.md?model=05608IJ), [All aircraft, 261 cases](https://openairdocs.org/ntsb-events/097/sequence.md)
- [Initial climb: Loss of engine power (total)](https://openairdocs.org/ntsb-events/341); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-events/341/sequence.md?model=05608IJ), [All aircraft, 3,820 cases](https://openairdocs.org/ntsb-events/341/sequence.md)
- [Initial climb: Powerplant sys/comp malf/fail](https://openairdocs.org/ntsb-events/340); cases with it: [Payne Tim G/ Payne Joseph L EXEC 162-F, 1 case](https://openairdocs.org/ntsb-events/340/sequence.md?model=05608IJ), [All aircraft, 820 cases](https://openairdocs.org/ntsb-events/340/sequence.md)

## Analysis

The pilot reported that, while the experimental, amateur-built helicopter was climbing through 300 feet, he heard a loud "bang" come from the rear compartment and that the helicopter subsequently yawed right. He made an emergency autorotation landing to a field. During the landing, the helicopter's skids sunk into the mud, and the main rotor blades contacted the ground. The helicopter then came to rest on its side. A postaccident examination of the helicopter revealed that the main rotor belt was not approved for aircraft use and that it was broken straight across in a crimp-type failure. According to the belt manufacturer, belt crimping damage is "commonly associated with belt mishandling, inadequate belt installation tension, sub-minimal sprocket diameters, and/or entry of foreign objects within the belt drive." No foreign object preimpact damage was found. Further, although the belt was an unapproved part, it should have been inspected during each 25-hour standard inspection and the belt tension was to be tested during each annual inspection. At the time of the accident, the belt had accumulated 215.9 total hours. Based on this evidence, the pilot installed an unauthorized main rotor drive belt and then failed to properly inspect the belt, which resulted in inadequate belt tension, the belt's failure, and the subsequent loss of engine power.

## Factual narrative

On June 21, 2014, about 1030 eastern daylight time, an experimental-amateur built Rotorway Exec 162F helicopter, N6828D, made a forced landing and rolled over following a loss of engine power near the Indianapolis Regional Airport (KMQJ), Indianapolis, Indiana. The pilot and one passenger were not injured. The helicopter sustained substantial damage. The helicopter was registered to and operated by a private individual under the provisions of 14 Code of Federal Regulations Part 91 as a personal flight. Visual meteorological conditions prevailed and no flight plan was filed. The flight was originating at the time of the accident and was destined for the Goshen Municipal Airport (KGSH), Goshen, Indiana. The pilot reported that he and his daughter departed in the helicopter to the north. While climbing through 300 feet, he heard a loud "bang" from the rear compartment and the helicopter yawed to the right. The pilot made an emergency autorotation into a field ahead. During the landing, the helicopter's skids sunk into the mud, the main rotor blades contacted the ground and it rolled onto its side, which resulted in substantial damage. A postaccident examination of the helicopter revealed that the main rotor belt was broken straight across. There was no evidence of preimpact damage from foreign objects. The pilot later reported that he installed the main rotor belt on June 15, 2003, at a Hobbs time of 155.5 hours. At the time of the accident the belt had accumulated 215.9 total hours. The belt was to be inspected during each 25 hour standard inspection and the belt tension was to be tested during each annual inspection. The belt did not have a required replacement time; the recommended replacement time was 500 hours. The Rotorway Exec162F Helicopter Maintenance Manual specifies part number E23-1210: Main Drive Belts, which is a part that is available from Rotorway. The belt used on the accident helicopter was manufactured by Gates and was not approved for aircraft use. The Gates Parts Catalog included an "Aircraft Policy" which stated: "WARNING! BE SAFE! Do not use Gates belts, pulleys or sprockets on aircraft propeller or rotor drive systems or in-flight accessory drives. Gates products are not designed or intended for aircraft use." Gates also produced a "Synchronous Belt Failure Analysis Guide" in order to accurately determine belt failure modes. The "Belt Crimp Failures" section stated in part: "A "crimp" type belt failure often resembles a straight tensile failure as illustrated in Figure 3. A straight type of break like this may occur when belt tensile cords are bent around an excessively small diameter. A sharp bend may result in large compressive forces within the tensile members causing individual fibers to buckle or crimp, reducing the overall ultimate tensile strength of the belt. Belt crimping damage is most commonly associated with belt mishandling, inadequate belt installation tension, sub-minimal sprocket diameters, and/or entry offoreign objects within the belt drive."

## Aircraft

- Registration: [N6828D](https://openairdocs.org/deregistered/N6828D-2018-03-02), registration cancelled 2018-03-02, S/N 6460, built 2000 (OpenAirDocs)
- Reported make and model: ROTORWAY EXEC 162F
- Registry model: [Payne Tim G/ Payne Joseph L EXEC 162-F](https://openairdocs.org/model/payne-tim-g-payne-joseph-l-exec-162-f) (registry code 05608IJ) (OpenAirDocs)
- Registry engine: [Rotorway RW-145 series](https://openairdocs.org/engine/rotorway-rw-145-series) (registry code 55005, reciprocating) (OpenAirDocs)
- Category: Helicopter, amateur-built
- Serial number: 6460
- Year built: 2000
- Engines: ROTORWAY RW-145 160 horsepower reciprocating
- Damage: Substantial damage
- Flight: Personal, Part 91
- Operator: Tim G Payne
- Registered owner: Tim G Payne
- Airworthiness certificate: Special, Experimental (Special)
- Last inspection: Annual, January 14, 2014, 371 hours before
- Departed: MQJ, Mt. Comfort, IN
- Destination: GSH, GOSHEN, IN
- Airport: MQJ, Indianapolis Rgnl

## Flight crew

As NTSB recorded them. NTSB leaves out names.

- Pilot; age 49; injuries: none; private; medical: class 3, with waivers/limitations; last flight review May 21, 2014; seat: left; restraint: 3-point; flight hours: 478 total, 423 in this make and model, 405 as pilot in command, 7 in the last 90 days, 6 in the last 30 days

## Weather

- Conditions: Visual (VMC), Day
- Wind: 350° at 5 knots
- Visibility: 10 statute miles
- Lowest ceiling: none
- Temperature: 79 °F, dew point 70 °F
- Altimeter: 29.95 inHg
- Observed at: KGEZ, 17 nm away

## 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 20140621010309A](https://openairdocs.org/incident/20140621010309A), Jun 21, 2014: Payne Tim G/ Payne Joseph L EXEC 162-F, Mccoordsville, IN, Substantial damage. June 21, 2014 at approximately 10:00 a.m. local time, an experimental amateur built rotorway exec 162-F helicopter, serial number 6460, suffered substantial…

## Docket (9 files)

The files NTSB released with the investigation on August 7, 2014, on NTSB's docket system: https://data.ntsb.gov/Docket?ProjectID=89511. 7.5 MB in all.

- Pilot/Operator Aircraft Accident Report, NTSB Form 6120.1 (item 1, .PDF, 230 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414811&FileExtension=.PDF&FileName=Pilot%2FOperator%20Aircraft%20Accident%20Report,%20NTSB%20Form%206120.1-Redacted.PDF
- FAA Inspector - Accident Information (item 2, .PDF, 540 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414812&FileExtension=.PDF&FileName=FAA%20Inspector%20-%20Accident%20Information-Redacted.PDF
- Memorandum for Record - Pilot Letter to FAA (item 3, .PDF, 18 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414814&FileExtension=.PDF&FileName=Memorandum%20for%20Record%20-%20Pilot%20Letter%20to%20FAA-Master.PDF
- Aircraft Maintenance Logbook Excerpts (item 4, .PDF, 469 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414815&FileExtension=.PDF&FileName=Aircraft%20Maintenance%20Logbook%20Excerpts-Redacted.PDF
- Gates Belt Failure Analysis Report (item 5, .PDF, 386 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414816&FileExtension=.PDF&FileName=Gates%20Belt%20Failure%20Analysis%20Report-Master.PDF
- Gates Part Catalog Introduction (item 6, .PDF, 884 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414817&FileExtension=.PDF&FileName=Gates%20Part%20Catalog%20Introduction-Master.PDF
- Rotorway Exec162F Helicopter Manual (item 7, .PDF, 2.4 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414818&FileExtension=.PDF&FileName=Rotorway%20Exec162F%20Helicopter%20Manual-Master.PDF
- Photo 1. Broken Belt (Photo Courtesy of FAA) (item 8, .PDF, 2.4 MB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414820&FileExtension=.PDF&FileName=Photo%201.%20Broken%20Belt%20(Photo%20Courtesy%20of%20FAA)-Master.PDF
- Photo 2. Main Wreckage (Photo Courtesy of FAA) (item 9, .PDF, 150 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40414821&FileExtension=.PDF&FileName=Photo%202.%20Main%20Wreckage%20(Photo%20Courtesy%20of%20FAA)-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.

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