Return-Path: Sender: (Marvin Kaye) To: lml Date: Fri, 28 Jun 2002 08:27:28 -0400 Message-ID: X-Original-Return-Path: Received: from imo-r01.mx.aol.com ([152.163.225.97] verified) by logan.com (CommuniGate Pro SMTP 4.0b4) with ESMTP id 1515706 for lml@lancaironline.net; Fri, 28 Jun 2002 02:07:25 -0400 Received: from Epijk@aol.com by imo-r01.mx.aol.com (mail_out_v32.21.) id q.151.10082a93 (14376) for ; Fri, 28 Jun 2002 02:07:22 -0400 (EDT) From: Epijk@aol.com X-Original-Message-ID: <151.10082a93.2a4d571a@aol.com> X-Original-Date: Fri, 28 Jun 2002 02:07:22 EDT Subject: [LML] URGENT SAFETY NOTICE for ENGINEAIR V8 USERS X-Original-To: lml@lancaironline.net MIME-Version: 1.0 Content-Type: multipart/alternative; boundary="part1_151.10082a93.2a4d571a_boundary" X-Mailer: AOL 7.0 for Windows US sub 10512 --part1_151.10082a93.2a4d571a_boundary Content-Type: text/plain; charset="US-ASCII" Content-Transfer-Encoding: 7bit TO: All owners and operators of EngineAir V8 engines FROM: EPI, Inc. (Designer of the PSRU used on EngineAir V8) SUBJECT: PSRU on EngineAir V8 UNAIRWORTHY until input shaft replaced DETAILS: EPI Service Bulletin 260003 (http://www.epi-eng.com/SB-260003.htm) Gentlemen: As many of you probably already know, the June 2002 issue of Sport Aviation magazine contained an article about Tom Zedaker's Lancair 4, which told of a failure of the prop reduction gearbox in his aircraft. IN FACT, there have been TWO such failures. EPI has issued a service bulletin (SB 260003, available at the URL above) which gives the details and conclusions about these failures. The failure on Zedaker's aircraft occurred in October 2001. It was a sudden a nd complete breakage of the input shaft connecting the engine to the gearbox, following major modifications to the engine by the owner, and a subsequent period of severe abuse of the gearbox due to engine malfunction (see service bulletin for details). The article dismisses the failure by claiming that "...the gearbox...was not at all like the vastly superior units now supplied by EngineAir..." That claim is patently false. In fact, the only difference between the production units and the prototype gearbox (the one in Zedaker's airplane) is the gear ratio. All other structural and functional aspects are identical. In fact, the first fifteen units supplied by EngineAir were built with EPI parts. In point of fact, based on subsequent interactions EPI has had with EngineAir's vendors, there is a real concern that certain parts in subsequent units may be of significantly lower quality than those supplied by EPI. The second input shaft failure occurred at Sun n'Fun 2002, on a "production" gearbox, and which was caused by the retrofitting of EngineAir-manufactured parts (see service bulletin for details). Based on these two failures, EPI strongly believes that a serious safety issue exists. There is convincing evidence that both failures occurred as a result of abuse and improper assembly (see service bulletin for details). Nevertheless, EPI has designed a replacement input shaft which is more tolerant of such abuse. EPI notified EngineAir (in writing) about this issue and about the replacement parts over 6 weeks ago (May 15, 2002), and urged them to acquire the newly designed input shaft and retrofit all delivered gearboxes with it immediately. As of today (6/27/02), EngineAir has not acquired the new design and has expressed no interest in this safety issue. Therefore, EPI has no other recourse than to declare the Mark-9 PSRU UNAIRWORTHY until it is retrofitted with the replacement input shaft. Please see the service bulletin (URL: http://www.epi-eng.com/SB-260003.htm) for the complete information on this safety of flight issue. Contact EPI off line (jack@epi-eng.com) to obtain information about how to get the replacement part. Thank you. Jack Kane EPI, inc. --part1_151.10082a93.2a4d571a_boundary Content-Type: text/html; charset="US-ASCII" Content-Transfer-Encoding: 7bit TO: All owners and operators of EngineAir V8 engines
FROM: EPI, Inc. (Designer of the PSRU used on EngineAir V8)
SUBJECT: PSRU on EngineAir V8 UNAIRWORTHY until input shaft replaced
DETAILS: EPI Service Bulletin 260003 (http://www.epi-eng.com/SB-260003.htm)

Gentlemen:
As many of you probably already know, the June 2002 issue of Sport Aviation magazine contained an article about Tom Zedaker's Lancair 4, which told of a failure of the prop reduction gearbox in his aircraft. IN FACT, there have been TWO such failures. EPI has issued a service bulletin (SB 260003, available at the URL above) which gives the details and conclusions about these failures.

The failure on Zedaker's aircraft occurred in October 2001. It was a sudden and complete breakage of the input shaft connecting the engine to the gearbox, following major modifications to the engine by the owner, and a subsequent period of severe abuse of the gearbox due to engine malfunction (see service bulletin for details).

The article dismisses the failure by claiming that "...the gearbox...was not at all like the vastly superior units now supplied by EngineAir..."

That claim is patently false. In fact, the only difference between the production units and the prototype gearbox (the one in Zedaker's airplane) is the gear ratio. All other structural and functional aspects are identical. In fact, the first fifteen units supplied by EngineAir were built with EPI parts. In point of fact, based on subsequent interactions EPI has had with EngineAir's vendors, there is a real concern that certain parts in subsequent units may be of significantly lower quality than those supplied by EPI.

The second input shaft failure occurred at Sun n'Fun 2002, on a "production" gearbox, and which was caused by the retrofitting of EngineAir-manufactured parts (see service bulletin for details).

Based on these two failures, EPI strongly believes that a serious safety issue exists. There is convincing evidence that both failures occurred as a result of abuse and improper assembly (see service bulletin for details). Nevertheless, EPI has designed a replacement input shaft which is more tolerant of such abuse.

EPI notified EngineAir (in writing) about this issue and about the replacement parts over 6 weeks ago (May 15, 2002), and urged them to acquire the newly designed input shaft and retrofit all delivered gearboxes with it immediately.

As of today (6/27/02), EngineAir has not acquired the new design and has expressed no interest in this safety issue.

Therefore, EPI has no other recourse than to declare the Mark-9 PSRU UNAIRWORTHY until it is retrofitted with the replacement input shaft.

Please see the service bulletin (URL: http://www.epi-eng.com/SB-260003.htm) for the complete information on this safety of flight issue.

Contact EPI off line (jack@epi-eng.com) to obtain information about how to get the replacement part.

Thank you.
Jack Kane
EPI, inc. --part1_151.10082a93.2a4d571a_boundary--