# NTSB CHI03IA300: Cessna 650, N651EJ, Rapid City, SD, August 29, 2003 - Type: NTSB incident investigation - Classification: Incident · No injuries · Incident investigation · Final report - Date: August 29, 2003, 16:35 local (21:35 UTC) - Place: Rapid City, SD - Coordinates: 44.045276, -103.05722 - Nearby events: https://openairdocs.org/map.md?lat=44.0453&lon=-103.0572&mi=10 - Phase of flight: [Enroute](https://openairdocs.org/ntsb-phases/400) (OpenAirDocs' grouping) - Highest injury: No injuries - Injuries: 9 uninjured - Status: Completed, report June 2, 2004 - Report: Approved by Office Director - Parties: Rapid City, SD - NTSB case key (mKey): 57868 - NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=CHI03IA300 - NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/57868/pdf - Page: https://openairdocs.org/ntsb/CHI03IA300 ## Probable cause The in-flight failure of the right wing aileron cable during cruise. ## Sequence of events In NTSB's coding before 2008 (https://www.ntsb.gov/GILS/Documents/codman.pdf). - Airframe/component/system failure/malfunction, cruise - normal - remedial action - performed, pilot in command - flt control syst,aileron control cable/rod - failure,total (cause) ## Analysis A Cessna 650 experienced a right wing aileron cable failure while in cruise flight at FL390 approximately 200 miles southeast of Rapid City, South Dakota. The pilot in command reported that with the autopilot engaged, the airplane started a gentle roll to the right. The autopilot was disengaged and a approximate 40 degree control wheel deflection to the left was made to keep the wings level. The right aileron did not seem to move with control wheel deflection. The right roll control spoiler did respond to control wheel inputs. All left control surfaces appeared to function normally. The pilots consulted all control malfunction checklists, and there were no changes noted. The pilots decided to continue to the destination. An uneventful, full-flap landing was made at Rapid City Municipal Airport. Maintenance personnel discovered a completely broken right outboard aileron cable. The right aileron cable (Part Number 6260106-25) underwent a metallurgical examination. The wire stands displayed sheared and cut ends due to pinching as if the cable came off its large diameter pulley and was pulled over a small radius and pinched. Only a few tensile cup cone fractures were found, indicating nearly all the wire strands had been sheared or cut prior to final tensile separation of the few remaining strands. ## Factual narrative On August 29, 2003, at approximately 1635, a Cessna 650, N651EJ, experienced a right wing aileron cable failure while in cruise flight at FL390 approximately 200 miles southeast of Rapid City, South Dakota. The airline transport (ATP) rated pilot in command, the ATP rated co-pilot, and seven passengers on board were not injured. The 14 CFR Part 91 business flight was operating on an instrument flight rules flight plan in visual meteorological conditions. The flight originated from Marion, Illinois, about 1500 with the intended destination of the Rapid City Regional Airport (RAP). The pilot in command reported that with the autopilot engaged, the airplane started a gentle roll to the right. The autopilot was disengaged and an approximate 40 degree control wheel deflection to the left was made to keep the wings level. Positive roll control was available; however, the right aileron did not seem to move with control wheel deflection. The right roll control spoiler did respond to control wheel inputs. All left control surfaces appeared to function normally. The pilots consulted all control malfunction checklists, and there were no changes noted. The pilots decided to continue to destination with minimum maneuvering, for a straight in approach at RAP on runway 32 (8,600 feet long) with the wind closely aligned with the runway. The pilot in command noted that the airplane responded well to roll control inputs at lower airspeeds. An uneventful, full-flap landing was made at RAP. Maintenance personnel discovered a completely broken right outboard aileron cable. The right aileron cable (Part Number 6260106-25) underwent a metallurgical examination at Engineering Systems Inc. (ESI), Aurora, Illinois. ESI reported that the examination of the right aileron showed that the fracture ends were covered in grease and required cleaning using an ultrasonic cleaner with acetone. The cleaned wire stands displayed sheared and cut ends due to pinching. ESI further stated, these fractures are all typical of a wire rope cable coming off its large diameter pulley and being pulled over a small radius and being pinched. This creates the wear and loads necessary to start fracturing the outer strands and working in toward the center. Only a few tensile cup cone fractures were found, indicating nearly all the wire strands had been sheared or cut prior to final tensile separation of the few remaining strands. According to maintenance records, the airplane completed a phase 1-5 Citation continuous inspection program on June 25, 2003. The aileron cables and pulley assemblies were inspected at this time. ## Aircraft - Registration: [N651EJ](https://openairdocs.org/aircraft/N651EJ), registered now, S/N 650-0241, built 1995 (OpenAirDocs) - Reported make and model: Cessna 650 - Registry model: [Cessna 650](https://openairdocs.org/model/cessna-650) (registry code 2076802) (OpenAirDocs) - Registry engine: [Garrett TFE731 series](https://openairdocs.org/engine/garrett-tfe731-series) (registry code 29001, turbo-fan) (OpenAirDocs) - Category: Airplane - Serial number: 650-0241 - Airframe hours: 4705.7 - Engines: Garrett TFE-731-3C 3481 lbs thrust turbo fan; Garrett TFE-731-3C 3480 lbs thrust turbo fan - Damage: No damage - Flight: Business, Part 91 - Operator: Three Angels Broadcasting Network - Registered owner: Fleet Capital, INC. - Airworthiness certificate: Standard, Normal - Last inspection: Continuous airworthiness, June 25, 2003, 56.4 hours before - Departed: MWA`, Marion, IL - Destination: RAP, Rapid City, SD - Flight plan: IFR - Airport: RAP, Rapid City Regional, runway 32, 8,701 × 150 ft, concrete ## Flight crew As NTSB recorded them. NTSB leaves out names. - Pilot; age 52; injuries: none; airline transport, flight instructor; airplane ratings: multi-engine land, single-engine land; instrument ratings: airplane; medical: class 1, valid medical--w/ waivers/lim; last flight review June 27, 2003; seat: left; flight hours: 15,500 total, 40 in this make and model, 14,000 as pilot in command, 100 in the last 90 days, 35 in the last 30 days, 2 in the last 24 hours - Co-pilot; age 35; injuries: none; flight instructor, airline transport; airplane ratings: multi-engine land, single-engine land; instrument ratings: airplane; medical: class 1, valid medical--no waivers/lim.; last flight review June 13, 2003; seat: right; flight hours: 1,984 total, 40 in this make and model, 1,200 as pilot in command, 40 in the last 90 days, 20 in the last 30 days, 2 in the last 24 hours ## Weather - Conditions: Visual (VMC) - Wind: 30° at 11 knots - Visibility: 10 statute miles - Lowest ceiling: 7,500 ft overcast - Temperature: 61 °F, dew point 48 °F - Altimeter: 30.32 inHg - Observed at: RAP ## FAA reports on this event (1) The FAA's own accident and incident reports, matched to the aircraft by N-number and date (OpenAirDocs). - [Incident 20030829022269I](https://openairdocs.org/incident/20030829022269I), Aug 29, 2003: Cessna 650, Rapid City, SD. (-23) On Friday 8-29-2003 a Cessna model 650 N651EJ that was enroute from marion, IL to Rapid City, SD experienced a sudden roll at flight level 39K. The crew… 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.