# NTSB ERA09LA540: Flight Design Ctsw, N466CT, Gettysburg, PA, September 13, 2009

- Type: NTSB accident investigation
- Classification: Accident · No injuries · Limited investigation · Final report
- Date: September 13, 2009, 09:15 local (13:15 UTC)
- Place: Gettysburg, PA
- Coordinates: 39.84111, -77.274444 (estimated)
- Nearby events: https://openairdocs.org/map.md?lat=39.8411&lon=-77.2744&mi=10
- Phase of flight: [Landing](https://openairdocs.org/ntsb-phases/550) (OpenAirDocs' grouping)
- Defining event: [Landing: Landing gear collapse](https://openairdocs.org/ntsb-events/094)
- Highest injury: No injuries
- Injuries: 1 uninjured
- Status: Completed, report March 16, 2011
- Report: Approved by Office Director
- NTSB office: Eastern Region Aviation
- Parties: FAA/FSDO
- NTSB case key (mKey): 74822
- NTSB case page: https://web.ntsb.gov/investigations/?ntsbnumber=ERA09LA540
- NTSB report (PDF, downloads): https://data.ntsb.gov/carol-repgen/api/Aviation/ReportMain/GenerateNewestReport/74822/pdf
- NTSB docket: https://data.ntsb.gov/Docket?ProjectID=74822
- Page: https://openairdocs.org/ntsb/ERA09LA540

## Probable cause

The failure of the left main wheel attachment fitting due to overstress.

## Findings

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

- [Landing gear system: main landing gear](https://openairdocs.org/ntsb-findings/01023210): Aircraft › Aircraft systems · Design (probable cause); cases with it: [Flight Design CTSW, 1 case](https://openairdocs.org/ntsb-findings/01023210/cases.md?model=0600001), [All aircraft, 241 cases](https://openairdocs.org/ntsb-findings/01023210/cases.md)
- [Landing gear system: main landing gear](https://openairdocs.org/ntsb-findings/01023210): Aircraft › Aircraft systems · Capability exceeded (probable cause); cases with it: [Flight Design CTSW, 1 case](https://openairdocs.org/ntsb-findings/01023210/cases.md?model=0600001), [All aircraft, 241 cases](https://openairdocs.org/ntsb-findings/01023210/cases.md)
- [Design: equipment design](https://openairdocs.org/ntsb-findings/04011010): Organizational issues › Development · Manufacturer (probable cause); cases with it: [Flight Design CTSW, 1 case](https://openairdocs.org/ntsb-findings/04011010/cases.md?model=0600001), [All aircraft, 35 cases](https://openairdocs.org/ntsb-findings/04011010/cases.md)

## Sequence of events

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

- [Landing: Landing gear collapse](https://openairdocs.org/ntsb-events/094) (defining event); cases with it: [Flight Design CTSW, 6 cases](https://openairdocs.org/ntsb-events/094/sequence.md?model=0600001), [All aircraft, 1,787 cases](https://openairdocs.org/ntsb-events/094/sequence.md)
- [Landing-landing roll: Runway excursion](https://openairdocs.org/ntsb-events/300); cases with it: [Flight Design CTSW, 10 cases](https://openairdocs.org/ntsb-events/300/sequence.md?model=0600001), [All aircraft, 3,643 cases](https://openairdocs.org/ntsb-events/300/sequence.md)

## Analysis

During landing, the right main landing gear touched first, followed by the left main gear which was accompanied by an audible “thump.” The left main gear collapsed and the airplane veered off the edge of the runway. The left main landing gear attachment fitting was examined at the NTSB materials laboratory and no preexisting fractures were noted. The steel fitting was constructed from tubing and bar stock, and was powder-coated after fabrication. Examination revealed that the fitting failed due to overstress midway along the angled tube portion and that the fractures were consistent with bending loads experienced during landing and taxiing. The examination further revealed that the wall thickness was less than the manufacturer's specifications, and that the interior of the angled tube had been counter-bored prior to the powered coating and final assembly at the factory. Review of the NTSB database revealed that there were two additional accidents that occurred with identical damage incurred; in all instances, the parts failed from an overstress fracture that initiated in approximately the same location.

## Factual narrative

On September 13, 2009, about 0915 eastern daylight time, a special light sport Flight Design GMBH CTSW, N466CT, was substantially damaged following landing and a landing gear collapse at Gettysburg Regional Airport (W05), Gettysburg, Pennsylvania. The certificated private pilot was not injured. Visual meteorological conditions prevailed for the local personal flight, which originated at W05 at 0830, and was conducted under the provisions of Title 14 Code of Federal Regulations Part 91. In a telephone interview, the pilot stated that he had completed some “air work” in the local flying area prior to returning for landing on runway 24 at W05. While landing on the runway, with a right crosswind at 5 to 6 knots, and the flaps set at 15 degrees, the right main landing gear touched first. When the left main gear touched down, the pilot heard a “thump,” the left gear collapsed, and the airplane veered off the side of the runway. When asked to describe the landing on a scale of 1 to 10, the pilot described it as a “5” and said that the left main landing gear’s contact with the runway was similar to that of the right. A review of Federal Aviation Administration (FAA) airman records revealed that pilot held a private pilot certificate with a rating for airplane single engine land. His most recent FAA third class medical certificate was issued October 9, 1985. The pilot’s most recent flight review was completed on April 18, 2008. The pilot reported 190 total hours of flight experience, with 70 hours in the accident airplane make and model. According to FAA and maintenance records, the airplane was manufactured in 2007 and had accrued 90 total aircraft hours. Its most recent conditional inspection was completed August 29, 2009, at 82 total aircraft hours. The 0916 weather observation at Carroll County Airport (DMW), Westminster, Maryland, 19 miles southeast of the accident site, included clear skies and winds from 230 degrees at 6 knots. The visibility was 10 miles. The temperature was 24 degrees Celsius (C) and the dew point was 14 degrees C. The altimeter setting was 30.01 inches of mercury. Examination of the airplane at the scene by an FAA inspector revealed separation of the left main landing gear and substantial damage to the fuselage at the attach point. The gear was retained for examination at the National Transportation Safety Board (NTSB) materials laboratory in Washington, D.C. Data was downloaded from the Dynon Avionics D100 primary flight display for examination at the NTSB recorders laboratory, Washington, D.C. According to Dynon Avionics, the software version installed on the accident airplane "did not record data;" therefore, no accident flight data was recovered from the unit. The left main landing gear attachment fitting was examined at the NTSB materials laboratory, and no preexisting fractures were noted. The fitting was manufactured as an all-steel weldment constructed from tubing and bar stock, which was powder-coated afterfabrication. Examination revealed that the fitting failed due to overstress midway along the angled tube portion, and that the fractures were consistent with bending loads experienced during landing and taxiing. Examination further revealed that the wall thickness was less than the manufacturer's specification, and that the interior of the angled tube had been "counterbored" prior to powerdercoating and final assembly. Examination of the NTSB database revealed two additional accidents with identical damage and that in all three instances, the parts failed from an overstress fracture that initiated in approximately the same location.

## Aircraft

- Registration: [N466CT](https://openairdocs.org/aircraft/N466CT), registered now, S/N 07-02-12, built 2007 (OpenAirDocs)
- Reported make and model: FLIGHT DESIGN GMBH CTSW
- Registry model: [Flight Design CTSW](https://openairdocs.org/model/flight-design-ctsw) (registry code 0600001) (OpenAirDocs)
- Registry engine: [Rotax 912ULS series](https://openairdocs.org/engine/rotax-912uls-series) (registry code 55572, 4 cycle) (OpenAirDocs)
- Category: Airplane
- Serial number: 07-02-12
- Airframe hours: 90
- Engines: ROTAX 912ULS 100 horsepower reciprocating
- Damage: Substantial damage
- Flight: Personal, Part 91
- Operator: Groff Paul D
- Registered owner: Groff Paul D
- Airworthiness certificate: Special, Special light-sport (Special)
- Last inspection: Condition, August 29, 2009, 8 hours before
- Departed: W05, Gettysburg, PA
- Destination: W05, Gettysburg, PA
- Airport: W05, Gettysburg Regional, runway 24, 5,500 × 75 ft, asphalt

## Flight crew

As NTSB recorded them. NTSB leaves out names.

- Pilot; age 73; injuries: none; private, sport pilot; airplane ratings: single-engine land; medical: sport pilot; last flight review April 18, 2008; seat: left; flight hours: 190 total, 70 in this make and model

## Weather

- Conditions: Visual (VMC), Day
- Wind: 230° at 6 knots
- Visibility: 10 statute miles
- Lowest ceiling: none
- Temperature: 75 °F, dew point 57 °F
- Altimeter: 30.01 inHg
- Observed at: DMW, 18 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 20090913050179A](https://openairdocs.org/incident/20090913050179A), Sep 13, 2009: Flight Desi CTSW, Gettysburg, PA, Substantial damage. Upon landing the left main wheel attachment failed, resulting in the left main wheel departing the aircraft. Aircraft slid off the runway groundlooping and…

## Other investigations on N466CT (1)

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.

- [NTSB ERA16LA148](https://openairdocs.org/ntsb/ERA16LA148), Apr 6, 2016: Flight Design Ctsw (N466CT), Hilton Head Island, SC, substantial damage. Probable cause: The pilot's failure to apply carburetor heat following a loss of engine power due to carburetor icing.

## Docket (3 files)

The files NTSB released with the investigation on October 7, 2010, on NTSB's docket system: https://data.ntsb.gov/Docket?ProjectID=74822. 467 KB in all.

- Pilot/Operator Aircraft Accident Report, NTSB Form 6120.1 (Memo) (item 1, .PDF, 9 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40336023&FileExtension=.PDF&FileName=Pilot%2FOperator%20Aircraft%20Accident%20Report,%20NTSB%20Form%206120.1%20(Memo)-Master.PDF
- Record of Conversation with Pilot/FAA Inspector (item 2, .PDF, 56 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40336017&FileExtension=.PDF&FileName=Record%20of%20Conversation%20with%20Pilot%2FFAA%20Inspector-Master.PDF
- Materials Laboratory Factual Report 09-078 (item 3, .PDF, 402 KB): https://data.ntsb.gov/Docket/Document/docBLOB?ID=40336004&FileExtension=.PDF&FileName=Materials%20Laboratory%20Factual%20Report%2009-078-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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