The Saga of A Plane Gone Wrong

douglas393

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douglas
Not sure this is where to post so if it needs to be moved no problem. Sorry about the length.

I have not posted in a while, and though continued to fly, other issues kept me offline. Anyhow, I purchased a previously injured plane about 4 years ago, flipped on a landing. It was repaired by what I was told by my long term (over 10 years then) mechanic by a reputable repair shop. I had a prebuy done before purchase by my mechanic's shop (he was originally a small shop owner, but as he was winding down, he became an employee of a large well-respected avionics and maintenance company). Though he was involved in the prebuy, he did not do the majority of it. Anyhow, it came through the prebuy with only a few small squawks, no major issues, and nothing that was graded as good on their scale of good, average, and poor. After talking to the manager, the mechanics involved in the prebuy, and researching the squawks they identified I purchased the plane at a very good price compared to a similarly well-equipped plane of same vintage.

I have flown it for 4 years at this point, putting well over 200 hrs on the plane, and other than its tendency for a right-ward yaw (requiring a lot of left trim in cruise, and left rudder in take off) it has performed beyond my expectations in VMC, IMC, mild turbulence, powered on and powered off stalls, basic and commercial maneuvers, extreme slow flight, etc. It has gone through 3 subsequent annuals at the original shop, and though one was a disaster (discussed in a previous post) and no problems with the repairs were ever noted. and it was always declared airworthy. It had one extended search for an electrical (charging issue) which was finally fixed, though I was unhappy with how the search for the problem was done.

This year I relocated the plane from my airport to a new one in a different state, and so I had my annual done at this new airport with a new mechanic. He had done some minor work on the plane prior to the annual and was quite familiar with the plane. My interactions with him have always been positive, and he often helped me out without charging me. About 3 days after I left the plane with him, he called me and told me he had did a cursory inspection of the plane at most three hours) and was concerned that there were major issues with the repairs and 337 and he did not think the plane was airworthy. He asked me if I wanted him to do a more extensive inspection requiring about 30 to 40 hrs to document the issues and I agreed. This resulted in a 60+ page report documenting issue with both wings and the tail being out of spec, major rigging problems, wrong rivets and missing rivets, necessary repairs not performed, repairs not done correctly, discrepancies (wrong part numbers, missing part numbers, undocumented repairs, etc) on the 337, and other issues. I spoke to the wing repair shop who he consulted, and they confirmed his findings on the wings and tail after reviewing his report (which included numerous pictures).

Bottom line just for the wings and tail the needed repairs will require at least 6 months. For the other known issues, and unknown issues, who knows how long.

I contacted AOPA legal services, and they gave me a list of possible lawyers, recommending one in particular. I contacted this well known for his aviation work lawyer and after a number of correspondences he basically told me he could take on the case, I would almost definitely win, but at the end of the day the cost of the suit would be so high, my return would be net negative.

I then contacted the original shop who did the prebuy, and subsequent annuals, and their answer was the prebuy was inadequate given the previous damage to the plane (which they knew about and even documented in the prebuy) and they did not know how some of the issues missed on subsequent annuals. Their offer was to have me get the plane to them, they would inspect it, get the needed repairs done, and give me an undisclosed discounted labor rate! My insurance compnay obviously said it was not covered, unless there was a subsequent accident after I purchased the plane.

At this point, I am going to end up selling the plane, at a price about 2/3 what I paid for it, lick my wounds, and try to decide whether I will ever fly a plane again.

Sorry about the long post. Thought I did everything right, but in retrospect not too sure. I think the moral of the story is a bargain often is not a bargain at all. It is sad because this bird is an awesome plane, I loved flying it, it has given me memories that are certainly priceless, but in its present condition, it is certainly not airworthy and requires more money and time than I want to invest. I hope the purchaser does do it justice and it will be airworthy and flying again.

Thanks for letting me vent. Appreciate any thoughts, comments, questions, etc.
 
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At this point, I am going to end up selling the plane, at a price about 2/3 what I paid for it, lick my wounds, and try to decide whether I will ever fly a plane again.

Sorry about the long post. Thought I did everything right, but in retrospect not too sure. I think the moral of the story is a bargain often is not a bargain at all. It is sad because this bird is an awesome plane, I loved flying it, it has given me memories that are certainly priceless, but in its present condition, it is certainly not airworthy and requires more money and time than I want to invest. I hope the purchaser does do it justice and it will be airworthy and flying again.

Thanks for letting me vent. Appreciate any thoughts, comments, questions, etc.

Not sure if I missed what type of plane it is... but considering what's determined not to be airworthy, if it was my plane I'd jump at the opportunity to sell it and get back 2/3rds of the original investment. I have a feeling that may be an optimistic amount of return on your investment. Good luck, you are experiencing the dark side of GA ownership.
 
i feel your pain, sorry for your troubles.
One part of a pre buy is a pilot flying the plane and detecting unusual flight characteristics… such as the trim issues you note (left rudder on take off would deserve investigating).
 
i feel your pain, sorry for your troubles.
One part of a pre buy is a pilot flying the plane and detecting unusual flight characteristics… such as the trim issues you note (left rudder on take off would deserve investigating).
No more pre buys for me.
Annual it. Too much bs on pre buys.
Not that an annual will catch everything I know.

Certainly do a pre buy but roll that into an annual if passed pre buy.
 
Not sure if I missed what type of plane it is... but considering what's determined not to be airworthy, if it was my plane I'd jump at the opportunity to sell it and get back 2/3rds of the original investment. I have a feeling that may be an optimistic amount of return on your investment. Good luck, you are experiencing the dark side of GA ownership.
Previous post from me would show it is a T206H 2009. It is really a beautiful plane with numerous upgrades that makes it quite unique. As for the opportunity to sell, I have a deal in the works, but really am sad to lose the plane. I have been in GA for over 15 years and this is my second plane. Not sure this is a dark side as much as a wake up call, that even when you think you are making sure all your I's are dotted and your T's are crossed often your decision is based on findings you depend on other people for and you can only hope their findings are accurate and complete. The shop that did the prebuys and subsequent three annuals is a location of a large Avionics and Maintenance company with a stellar reputation. I put my trust in my long term (over 10 years) mechanic who never had steered me wrong before.
 
M2C

This is a lot for you to digest. So...... don't do anything. For a while that is; maybe a month. Let it settle a bit, and then you can look at this in a "quieter" frame of mind. Get a ferry permit, get yet another POV maybe.

Key questions will be are what things are wrong that are more "paper work", and what things are wrong that really matter in the real world. Is the frame tweaked that you need to use left trim, but otherwise flies fine, you can live with that. If the plane can't be put in perfect trim but none the less flies well for you, you can live with that. Is a part "wrong" because it works fine but has the wrong part number, ......

If the wrong rivets used are not strong enough, OK, let's change those.

You might decide to keep it or sell it, but again I'd wait a bit and then decide. BTW - if you decide to sell it, do a full disclosure to the new buyer.
 
Take it back to the last annual mechanic and annual it keep flying.
The last annual mechanic, who did the previous annuals, is no longer associated with the shop. I sent the report from my new mechanic to the shop, and they agree that they missed these issues, and the plane is indeed not airworthy, and without the identified deficiencies being addressed and corrected/repaired that it cannot be declared airworthy. So legally this is not an option.

Even if they were willing to declare it airworthy without the repairs, I am unwilling to fly a plane that has the issues this plane has. Whether or not it is safe, is not the issue, as I am told it is not in danger of catastrophic event causing an inflight break-up, but these issues need to be addressed and not ignored. I am not willing to become a statistic, or tempt the Swiss cheese model.
 
Ferry Permit. Agree with this....
Dr. Chien... Maybe you missed the part of my post where I said the shop I originally had do the prebuy, and subsequent three annuals agrees with the findings of my new mechanic, but if you did not...Really, I think you know who I am, or what I do as a profession. This would be like me suggesting to someone who cannot pass a medical with one AME to find another who is willing to ignore the issues preventing the successful medical and giving them a cleared medical. You would rip me apart and appropriately. The plane clearly needs a lot of work, and no one disputes this, and in its present state cannot be declared airworthy.

As far as taking the plane to the original shop, I do not want them to touch the plane for my use. Given everything they missed I am not sure I would trust them to take out my garbage for garbage pick-up.
 
i feel your pain, sorry for your troubles.
One part of a pre buy is a pilot flying the plane and detecting unusual flight characteristics… such as the trim issues you note (left rudder on take off would deserve investigating).
Did about a one hour prebuy flight. Was in the left seat. Did not do the take-off roll as this was my first flight in a 206, did straight and level, descent and assent, slow flight, and various turns. Did not notice the characteristics then. In fact, for the insurance company, had to do 5 hours in the plane with an instructor that they could certify was to their standards in flying a T206H, and did not notice it then either. All of these flights were at near maximum weight, and the trim issues are much more noticable at lower weights. Also, the plane has tip tanks and this affects it as well. If I remember correctly, after I put fuel in the tip tanks for the first time the left wing had fuel and the right did not (did not think about this until now). I discussed this with my mechanic(s) as well as other when I first noticed it and was told it was just an unusual flight characteristic of the plane, and nothing to be concerned about. Live and learn.
 
Some of the worst maintenance I’ve had came from those. Not that it makes any difference, though.
I had always used small shops prior to this and only went to them because that is where my mechanic went. I do not disagree.
 
M2C

This is a lot for you to digest. So...... don't do anything. For a while that is; maybe a month. Let it settle a bit, and then you can look at this in a "quieter" frame of mind. Get a ferry permit, get yet another POV maybe.

Key questions will be are what things are wrong that are more "paper work", and what things are wrong that really matter in the real world. Is the frame tweaked that you need to use left trim, but otherwise flies fine, you can live with that. If the plane can't be put in perfect trim but none the less flies well for you, you can live with that. Is a part "wrong" because it works fine but has the wrong part number, ......

If the wrong rivets used are not strong enough, OK, let's change those.

You might decide to keep it or sell it, but again I'd wait a bit and then decide. BTW - if you decide to sell it, do a full disclosure to the new buyer.
Been digesting this since January. Have gotten a number of POV and everyone agrees with the findings and conclusions of my new mechanic. This includes a wing repair shop that assisted my mechanic, the original shop who did the prebuys and previous annuals, as well as another mechanic I showed the report to. It is much more than paperwork, and a few rivets. It is both wings, hundreds of rivets, and the tail, and then there is the unknown. It goes without saying that I have been brutally honest with the buyers, to the point that I sent them the report my new mechanic made, allowed them to talk to my new mechanic, and had them do their own inspection of the plane. I would not have it any other way.
 
Many new GA owners learn this the hard way. Structural repairs from an accident are major surgery and require a higher level of skill than routine maintenance.
Not a new GA owner. Agree with your statement otherwise. I checked out the repair shop that did the repairs, and from everything I could find at the time suggested they were competent and well respected in doing such work. Obviously, in this case that is not true. Have attempted to contact them, and they are no longer in business, and the mechanic that supervised, and did the repairs has not responded to requests to contact me.
 
I would think most legacy C206 have battle damage. They work hard and use unimproved fields. If you like the plane find a 206 shop to fix and check the rigging.
 
I would think most legacy C206 have battle damage. They work hard and use unimproved fields. If you like the plane find a 206 shop to fix and check the rigging.
Not a legacy. 2009 vintage. No unimproved off field landings. I have from the G1000 its entire flight history. Was a float plane at one time but not now. Unfortunately the rigging is probably one of the lesser issues.
 
That's called "life."

As Jim Croce sang, "sometimes they say that you eat the bear, but sometimes the bear eats you" ...

Take what you can get for it and move along. No need to stress yourself further over things that you can't change.
 
That's called "life."

As Jim Croce sang, "sometimes they say that you eat the bear, but sometimes the bear eats you" ...

Take what you can get for it and move along. No need to stress yourself further over things that you can't change.
Yep. That is where I am now but it certainly hurts to get eaten by the bear.
 
Sorry you're going through this.

Just curious, if you're willing to share, what's wrong with the rivets? Wrong length? Wrong size? Wrong type entirely?
Wrong type, missing, poorly placed, too small for hole they are in...a combination of all.
 
Wow. Messy. I would like to know who was used for the pre buy "inspection". Major problems like you say are a main focus of a pre buy.

Im going through the same deal with a boat right now. Hasnt moved in 16 months and $44k. Going to need another $20k to get it right. I bought it cheap and now paying the price for my mistake.
 
Unless you are going to sell and not buy another plane I'd get it fixed, especially since you really like the plane. It never seems to work out positively selling and buying another supposedly "turn key" airplane that actually has its own list of problems.

Or maybe you want to get things really clean to take some more pictures. So you take the cowling off and while doing so you accidentally loosen up some fuel lines. It could be night time and to check for the strange smell you use your cigarette lighter for illumination since your flashlight was dead. Maybe you step on a stray socket on the ground and your lighter holding arm extends into the engine bay....
 
This resulted in a 60+ page report documenting issue with both wings and the tail being out of spec, major rigging problems, wrong rivets and missing rivets, necessary repairs not performed, repairs not done correctly, discrepancies (wrong part numbers, missing part numbers, undocumented repairs, etc) on the 337, and other issues.
Good job for taking the time to further detail the issues you faced vs leaving it at your initial post to stir the peanut gallery as most seem to do. No one learns from that latter type of post. But I am curious on several of your details given I’ve structurally repaired many aircraft over the years to include wings.
A couple questions for more context:
1) What were the repair manual references used on the repair 337s you note above?
2) Does your report list any specific examples of the undocumented repairs, necessary repairs not performed, or wrong/missing part numbers on the 337?
3) Why are you selling this aircraft?
 
Wrong type, missing, poorly placed, too small for hole they are in...a combination of all.
Yikes.

Regarding the 60+ page report documenting discrepancies, I'd hope the mechanic was including some kind of reference to a structural repair manual when marking a rivet as "wrong." As in, "Rivet length incorrect per SRM chapter 6, paragraph 3." I have limited experience in structural repair, but I have seen differences between what the manual requires, and what a specific mechanic "thinks" is required.

That said, given the volume of scope of all the discrepancies, I suppose the above may not matter.

Out of my lane a bit here, but if this supposedly reputable shop botched your ship this bad, it seems like it may be worthwhile at some point to involve the local FSDO. Surely, yours wasn't the only aircraft that got so screwed up........
 
Unless you are going to sell and not buy another plane I'd get it fixed, especially since you really like the plane. It never seems to work out positively selling and buying another supposedly "turn key" airplane that actually has its own list of problems.

Or maybe you want to get things really clean to take some more pictures. So you take the cowling off and while doing so you accidentally loosen up some fuel lines. It could be night time and to check for the strange smell you use your cigarette lighter for illumination since your flashlight was dead. Maybe you step on a stray socket on the ground and your lighter holding arm extends into the engine bay....
The plane from the outside is nearly perfect. Unfortunately, it is the insides that matter. Not willing to go down the rabbit hole as my mechanic, and the wing expert who viewed his report says that there is a probability of more issues being discovered when the repairs start. That being said it will be at least 6 months before the wings and tail are finished, and there is other issues as well.

Insurance fraud leads to jail time, and jail time would seriously impact any flying in the future!
 
Yikes.

Regarding the 60+ page report documenting discrepancies, I'd hope the mechanic was including some kind of reference to a structural repair manual when marking a rivet as "wrong." As in, "Rivet length incorrect per SRM chapter 6, paragraph 3." I have limited experience in structural repair, but I have seen differences between what the manual requires, and what a specific mechanic "thinks" is required.

That said, given the volume of scope of all the discrepancies, I suppose the above may not matter.

Out of my lane a bit here, but if this supposedly reputable shop botched your ship this bad, it seems like it may be worthwhile at some point to involve the local FSDO. Surely, yours wasn't the only aircraft that got so screwed up........
The report is very detailed, with both written descriptions and photographs. Included are photographs documenting discrepancies with measurements where possible. It is quite impressive.
 
Good job for taking the time to further detail the issues you faced vs leaving it at your initial post to stir the peanut gallery as most seem to do. No one learns from that latter type of post. But I am curious on several of your details given I’ve structurally repaired many aircraft over the years to include wings.
A couple questions for more context:
1) What were the repair manual references used on the repair 337s you note above?
2) Does your report list any specific examples of the undocumented repairs, necessary repairs not performed, or wrong/missing part numbers on the 337?
3) Why are you selling this aircraft?
The repair manuals my mechanic in NY were the official Cessna manuals as well as personal communications he had with Cessna when he had questions about how the repairs were done. His report includes the communications with Cesna/Textron as well as pictures and written descriptions of his findings. I am selling because of the extent of the needed repairs, and the time and money it will take. I do love the plane, but sometimes you need to cut ties no matter how much it hurts.
 
The repair manuals my mechanic in NY were the official Cessna manuals
So are you saying for the original repair 337 14 years ago they stated they used Cessna manuals? Would you happen to know if it specifically was the post 1996 Cessna Structural Manual?
 
So are you saying for the original repair 337 14 years ago they stated they used Cessna manuals? Would you happen to know if it specifically was the post 1996 Cessna Structural Manual?
Sorry about the confusion. The plane is a 2009 T206H not a legacy plane, and the repairs were completed 4 years ago. As for what the repair shop used I do not know, my mechanic however referred to them when making his report. I never asked nor thought to ask the repair mechanic what he used. I had been told by a number of people (including my mechanic who I have a greater than 10 year relation with no issues whatsoever) who had dealt with him in the past that he did good work.
 
Wow, so someone balled up a 3 year old 206?
The plane is a 2009 T206H, and they screwed up the landing in 2021. I have the G1000 data from the landing and they were almost 20 knots over the correct speed on final and so they porpoised and then flipped. I bought the plane about a year after the accident. The pilot was new to the aircraft. It is a pity.
 
Be carful
The plane is a 2009 T206H, and they screwed up the landing in 2021. I have the G1000 data from the landing and they were almost 20 knots over the correct speed on final and so they porpoised and then flipped. I bought the plane about a year after the accident. The pilot was new to the aircraft. It is a pity.
These things happen. Note the tail number for future purchases.
IMG_0605.webp
 
How exactly did your new mechanic get started down this rabbit hole?

From my POV as a mechanic, this thread is loaded with rage bait, but it’s quite short on details that matter.

It sounds like nobody thinks the airplane is gonna be falling out of the sky. That is half of the battle complete.
 
How exactly did your new mechanic get started down this rabbit hole?

From my POV as a mechanic, this thread is loaded with rage bait, but it’s quite short on details that matter.

It sounds like nobody thinks the airplane is gonna be falling out of the sky. That is half of the battle complete.
I had used a shop on my home base for the prebuy evaluation and subsequent three annuals. When I relocated the plane to a new home base, I used a new shop at this location for my annual this year. As part of the annual, he did a preliminary inspection of the plane and documents. Prior to this, he only had done an oil change and replaced a nonfunctioning oil heating element on the plane. He immediately discovered discrepancies in the 337, as well as issues with the wings. He called me to inform me that he could not state the plane was airworthy but did not know the extent of the issues. He told me I could get a second opinion or have him do a more complete inspection of the plane and get a better idea of what was wrong so that I could know what needed to be done to get it airworthy. I chose the latter, and this resulted in a 60+ page report of his findings. This report was seen by a number of other mechanics including the original shop, and a wing repair shop, and no one disputes his findings or conclusions.

Sorry you think my posts are rage bait. I do not believe it is. If it was, I would have mention names, etc. I think I pretty much laid out the facts without much emotion or commentary. Am I disappointed, yes. Am I happy with the situation, no. Do I think the original shop has done me a disservice, and should take responsibility, and accountability for their misses, yes. There is concern from the mechanic as well as those that reviewed his report that discovered the missed issues that a wing could fall off in flight given the issues he found. Certainly, its flight parameters for VA, VNO, and VNE are clearly affected. Also, because of the angles of the wings not being correct its stall characteristics, and tendency to spin, or spiral and recover are affected as well. Since I tend to be extremely conservative in my flying I fortunately did not experience any of this, but I also fly in an area where sudden turbulence, and pop-up storms are quite common, so the risk was certainly there. I also do a lot of maneuver practice, and this includes power on and power off stalls and the consequences thereof with altered stall characteristics.
 
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