Notes on Quad City Ultralights Challenger Safety

Walt Lounsbery, 12-31-2007

Collected statistics from Jan. 1, 1987 to today (a bit over 20 years)

Comparative Figures for NTSB Reports (Challenger is combined ultralight and aircraft report categories, others are aircraft category only):

Aircraft Search Phrase	Number of Reports
RV	423
Varieze	43
Quickie	58
Cub	27
Challenger	70

Note that the NTSB database search capability is very general.� Perhaps one in thirty of the RV reports are not for Van's Aircraft kit aircraft (I did not scan all reports to get a "clean" number on aircraft other than the Challenger).� The Challenger queries returned two reports for Bombardier Challenger business jets and a Challenger aerobatic aircraft.

Breakdown for Challengers

Type	Nonfatal	Fatal
Challenger I	3	2
Challenger II	45	20

Fatal Accidents

Date	Identification	Location	Analysis
6-4-1987	N56DZ	Red Granite, WI	Student pilot's second flight in aircraft that day after purchasing the aircraft.� Loss of control in downwind pattern at 150 to 200 feet AGL resulting in nose-down impact.
5-12-1990	None	East Moriches, NY	Pilot's first flight after final assembly of homebuilt.� Crashed on final approach.� Cause ruled as inadvertent stall with pilot's lack of training, experience, and qualification contributing factors.
4-8-1991	N283EL	Thomaston, GA	Aircraft experienced loss of engine power due to water in fuel and fouled spark plugs.� Pilot stalled aircraft during turn to return to runway.
5-9-1991	N425DE	Silt, CO	Weather, winds exceeding aircraft capability
10-13-1991	N8182K	Moriches, NY	Aircraft banked left and crashed on final approach.� Passenger reported inop right flaperon.
2-18-1993	N4391V	Boulder City, NV	Crashed 3 miles South of airport while returning to land.� Pilot, age 59, suffered from severe artery congestion and drug addiction at time of death.� NTSB ruled loss of control due to these factors.
2-22-1993	None	Quinton, VA	Crashed on turn to final approach.� Pilot, age 46, had revoked certificate due to �sustained permanent neurological injury� from a previous homebuilt accident.� Pilot was on several prescription drugs at time of death.� Winds were 18 knots and gusting to 22.
7-17-1995	None (Challenger I)	Anniston, AL	Engine sputtered on takeoff.� Aircraft stalled and crashed on turn back to airport.� Pilot had about 160 hours of experience with expired student pilots certificate and third class medical.
8-10-1995	N890JH	Madisonville, KY	Witnesses reported intermittent engine operation as the aircraft steeply descended to impact with the ground.� Pilot had 30 hours, but had not flown for two years before flying the aircraft with updated dual ignition.� Faulty ignition system modifications were confirmed post-crash.
9-8-1995	N838TG	Scappoose, OR	Pilot took off on runway 15 and announced intent to land on runway 33.� During turn aircraft rolled into a spin.� Parachute was deployed, but there was inadequate altitude for full deployment.� Aircraft was at or above its maximum gross weight.
6-7-1996	N2087P	Longview, TX	NTSB ruled cause as �failure to maintain airspeed�.� Narrative indicates poor control on landing leading to collision with nearby vehicles, a trailer, and a tree.
7-2-1996	N75489 (Challenger I)	Paso Robles, CA	On the aircraft�s first takeoff after completion, the lexan wing root cover separated at about 100 feet AGL, impacted the prop, and one propeller blade broke off.� Aircraft stalled and crashed.� Pilot was 74 and was denied medical certificate renewal in 1994 due to cardiovascular condition.� At death pilot was on prescription tranquilizers and antidepressants.
5-20-1997	None	Southern Pines, NC	The airplane collided with power lines after takeoff and crashed into a pond.� Passenger was unable to release the pilot�s lap belt before he drowned.� Pilot was intoxicated.
7-28-1997	N44LS	Bellaire, MI	Aircraft crashed on takeoff in a left turn spiral.� Winds were 7 knots gusting to 15.� Flight controls and engine appeared normal.
12-6-1997	N11644	Rainbow City, AL	Pilot was flying at low altitude and stalled into trees.� Pilot had about 5 hours training in another airplane, was not licensed.
5-3-1998	None	Savannah, GA	Aircraft crashed near the Savannah River, no witnesses.� The pilot had just purchased the aircraft and had no previous time in a Challenger.� Pilot was 65 with over 2400 hours.
11-8-1998	None	San Antonio, TX	70 year old passenger/co-pilot with known cardiovascular problems.� Pilot (age 50) stalled aircraft from crosswind to downwind.� Pilot had no prior experience in Challenger.
7-2-2001	N902GH	Sedalia, MO	Aircraft experienced engine trouble while flying in the vicinity of the airport and impacted trees.� Pilot had 100 total hours with about 2 hours on the plane since purchase.� Pilot was afraid to fly the aircraft with doors on, so removed the doors, added stab tip plates and rudder trim tab.� Crash occurred about 3 or 4 months since prior flight.
10-22-2001	N843C	Midland, VA	Aircraft crashed while on test flight after the pilot purchased and refurbished the airplane.� Aircraft crashed in a wooded area about � mile from the runway.� Witnesses reported that the engine was making an unusual noise prior to crash.
3-6-2004	None	Labelle, FL	Pilot executed two abrupt dives and recoveries, resulting in separation of the right wing.
3-26-2005	N4018G	La Grande, OR	Pilot flew into IMC in mountainous terrain, and subsequently impacted a mountain.� Weather factors included low ceilings, snow, obscuration, and gusty winds.
11-27-2007	N2159M	Apple River, IL	Preliminary report states that aircraft collided with terrain following a loss of control.

Fatal Accident Summary

Eight fatal accidents happened soon after purchase, modification of the aircraft, or otherwise due to lack of experience with Challengers.� Thirteen fatal accidents occurred in the pattern or near the airport.� Only two fatal accidents were attributable to weather.� Parachute was deployed at low altitude in one fatal accident.

Nonfatal Accidents

Date	Identification	Location	Analysis
2007
9-5-2007	N41734	Edgewood, NM	Aircraft began uncontrollable right yaw approx. 100 ft. AGL off departure end of the runway, leading to impact with the ground.� Flight controls were OK.� Pilot thought he had encountered a dust devil, several were reported in airport vicinity.
6-12-2007	N204DC	Lodi, CA	Right wing separated at 2000 ft. AGL due to incorrectly tightened Rony bracket/strut connection on the forward lift strut.� Pilot deployed BRS parachute and landed safely in grape vineyard.
3-18-2007	N7023D	Arecibo, PR	Aircraft crashed on takeoff due to aft control stick being tied to aft position by seat belts, preventing forward motion of the stick.
1-20-2007	None	Orland, CA	Aircraft is �Challenger Special.�� Engine lost power due to fuel exhaustion 2 miles from destination airport.� Pilot encountered headwinds and tried to make destination although alternates were available. Aircraft impacted trees in an orchard.
2006
11-21-2006	N44594	Bessemer, AL	Non-certified pilot, age 65, failed to control aircraft on approach with moderate gusty winds.� Hit a pine tree near the runway.
6-22-2006	None	Emmett, ID	Pilot�s first flight in a Challenger II.� Set full flaperon down for takeoff and could not achieve positive climb past the end of the runway.� Nose gear collapsed on landing in hay field beyond runway.
2-11-2006	N128RT	Apopka, FL	Left pontoon struck a submerged tree stump during a water landing.� The right wing support failed.
2005
12-21-2005	N115BT	California, MO	Unlicensed pilot was operating solo from the aft seat.� Entered a flat spin on base turn and impacted the ground.
10-8-2005	N8069J	Spokane, WA	Loss of all engine power on downwind.
2004
9-22-2004	N2079S	Lancaster, SC	Aircraft experienced partial power loss at 2,000 feet due to water in the fuel.� Aircraft impacted trees during the emergency landing in a small field.
2003
8-15-2003	N20EJ	Eldorado, TX	Issues with the forward throttle cable and control led to aborted takeoff and an overrun of the end of the runway, with subsequent impact with a tree.
2-3-2003	N851MY	Huntington, WV	Pilot tried to execute a dead-stick landing by switching off the engine on the base leg.� Realizing that he would not clear the trees off the approach end of the runway, he restarted the engine and applied throttle.� The resulting nose down pitch sent the aircraft into the trees.
2002
10-5-2002	None	Porterville, CA	Forced landing after takeoff due to loss of engine power.
9-1-2002	N521CF	Plymouth, FL	Application of power on final approach caused the airplane to dive to the right and collide with trees.
5-12-2002	N2NX	Lubbock, TX	Forced landing after takeoff due to loss of engine power at 200-300 ft. AGL.
2000
8-11-2000	N61881	Central, AK	Crashed during attempted takeoff in crosswinds of 18 knots gusting to 40.
7-23-2000	None	Chiloquin, OR	Forced landing due to loss of power.
1999
8-3-1999	N14131	Pahokee, FL	Forced landing due to loss of power at 500 ft. AGL after takeoff.� Transmission belt to propeller broke.
5-29-1999	N22FE	Douglas, WY	Aircraft banked to left after takeoff and impacted the ground.� Pilot reported that he had applied insufficient right rudder during takeoff at a slow airspeed.
4-7-1999	N929DB	Astatula, FL	Pilot was performing Phase I flight testing.� While descending through 4,000 feet MSL at about 115-118 MPH, flutter developed.� After reducing power and raising the nose, the aircraft experienced structural failure and rolled inverted.� The pilot activated the parachute system and landed in an orange grove.
1998
6-7-1998	N2NX	Pleasant Valley, AZ	Emergency landing following loss of power during cruise.� The engine had a broken spark plug retainer spring and loose spark plug wire cap.
5-11-1998	N199DD	Wayland, MI	Right forward lift strut attachment failed a 300 ft. AGL after first takeoff of the aircraft.� Attachment bolt was improperly installed through the strut fairing but not the strut itself.
1-20-1998	N266RP	Erwinville, LA	Engine lost power during downwind for landing.� The fuel pickup line had separated from the fuel tank.
1-17-1998	N132BC	Evergreen, AL	Emergency landing after the propeller assembly separated from the engine.
1997
10-1-1997	N19006	Lake City, MI	Forced landing into trees after power failure due to fouled spark plugs.
4-29-1997	N9213A	Mansfield, PA	Aircraft struck a power line on a low pass at a field.
1996
8-3-1996	N113JM	Toa Baja, PR	Power loss on takeoff due to water contaminated fuel
5-10-1996	N52898	Redmond, OR	Aircraft collided with the top wire of a fence on short final.
5-5-1996	N1591G	Talkeetna, AK	Forced landing due to loss of engine power.� Pilot leaned the rear cylinder mixture too much.
1995
9-3-1995	N4281D	Cedar Springs, MI	Power loss after takeoff due to fouled spark plugs (past change interval).� Aircraft tailwheel struck a power line during landing.
6-9-1995	N8101Z	Burlington, CT	Engine lost power in traffic pattern, descended and spun to the ground.� Throttles were found in idle position.� Neither instructor or student could remember the accident.
5-2-1995	N100GB	Bridgeport, MI	Approx. 500 ft AGL after takeoff, aircraft began uncontrollable left spiral into the ground.� First flight after installation of lexan doors.� Ruled due to loss of directional stability caused by installation of lexan doors.
1994
9-20-1994	None	Princeton, IL	Loss of control and subsequent crash ruled due to loss of directional stability caused by installation of lexan doors.
8-26-1994	N7051P	Fairfield, IA	Transmission belt failure at about 300 ft. AGL after takeoff, resulting in crash during forced landing.
5-21-1994	None	Islamorada, FL	Aircraft stalled twice during approach to landing, crashing on second stall.� Aircraft just had a float kit installed, and NTSB ruled the pilot did not properly control airspeed in turbulent conditions.
1993
11-28-1993	N4285V	Escanaba, MI	Forced landing due to an uncontrollable left bank.� Aircraft just had lexan doors installed.� Ruled due to loss of directional stability caused by installation of lexan doors.
8-21-1993	N771RH	Plymouth, WI	Aircraft was damaged in forced landing caused by loss of power during departure.
7-18-1993	N851BZ	Alamogordo, NM	Propeller shaft bearing seized, leading to separation of the propeller.� Aircraft crashed during forced landing.
7-12-1993	N415JR	Ottawa, IL	Forced landing due to power loss caused by a fouled spark plug.
3-11-1993	N3207C	Albuquerque, NM	Pilot was unable to roll out of a left turn from downwind to base.� Aircraft descended to impact with the ground.� Possible encounter with turbulence.
2-28-1993	None	Blaine, MN	Midair collision of a Challenger I with a Cessna 150.
1992
7-22-1992	N602CH	Burlington, CT	Pilot reported loss of power, causing a forced landing on a road, with subsequent collision with a street sign and telephone pole.� Engine ran OK post-crash and cause of power issue could not be determined.
4-27-1992	N4268R	Maize, KS	Pilot lost control on landing while maneuvering out of a bad approach.� Airplane collided with a fence.
3-21-1992	N30781	Fairbanks, AK	Aircraft became airborne during taxi test.� Pilot could not control the aircraft, which crashed.
2-7-1992	None	Blakesburg, IA	Airplane crashed during landing.� Winds were 23 knots with gusts to 29.
1991
7-4-1991	N503DB	Lebanon, IN	Power loss during overflight of airport, caused by a failed engine starter clutch.� Pilot stalled the aircraft at 30 ft. AGL during forced landing.
4-6-1991	N4555J	Bullhead City, AZ	Forced landing subsequent to propeller disintegration in flight.
1989
10-22-1989	N91269	Warrens, WI	Aircraft lost power shortly after departing a private strip.� Aircraft crashed during forced landing.� Engine had suffered a crankshaft failure.
1988
7-11-1988	N51012	Platteville, WI	Aircraft lost power after takeoff at 100 ft. AGL.� Aircraft was damaged in forced landing in a corn field.� Several bags and a purse were stowed on top of the fuel tank, possible restricting the fuel line.

Number of Accidents Each Year

Year	Nonfatal	Fatal
2007	4	1
2006	3	0
2005	2	1
2004	1	1
2003	2	0
2002	3	0
2001	0	2
2000	2	0
1999	3	0
1998	4	2
1997	2	3
1996	3	2
1995	3	3
1994	3	0
1993	6	2
1992	4	0
1991	2	3
1990	0	1
1989	1	0
1988	1	0
1987	0	1

Nonfatal Accident Summary

Only three nonfatal accidents were possibly caused by weather, generally high gusty winds.

Thirty-two accidents occurred near or at an airfield.� In general, these reports might not have included aircraft damage if the pilot had properly aborted a takeoff in climb phase or executed an engine-out landing with proper airspeed control.� Of course, situations like the midair with the Cessna 150 are different.

Three nonfatal accidents were ruled as caused by installation of Lexan doors.� Note that one fatality occurred after the Lexan doors were removed and tip plates were installed on the horizontal tail.

The parachute was deployed in two nonfatal accidents, saving lives.� Note that one fatality occurred when the parachute was deployed with inadequate altitude to be effective.

Twenty-two nonfatal accidents were attributable to problems with engine power, the transmission belt, or the propeller.� There were many cases of contaminated fuel, mainly due to water.

Two nonfatal accidents resulted from structural problems or failure.� In one case, the aircraft had been improperly constructed.� In the other, the pilot was performing high load maneuvers.

Eleven nonfatal accidents were only attributed to loss of control or failure to control.� Causes of this type without a failure or jam in the control system indicate that the control system may be inadequate or the pilot was not keeping proper airspeed.

Two nonfatal accidents were directly attributed to lack of experience in a Challenger.� Review of the accident reports indicates that poor training or experience (poor flying skills) contributed to the accident outcome even if some other factor initiated the event for most of the accidents.

Warning

I have assembled this data to improve my understanding of the history and capability of the Quad City Ultralights Challenger aircraft.� I do not warranty the accuracy of this document, or my conclusions.� You should examine the data directly before basing any actions on the accident history of the Challenger.� The NTSB reports were compiled from their database, which is available on the Web at:

http://www.ntsb.gov/ntsb/query.asp

Conclusion

Although the NTSB has ruled that installation of Lexan doors led to yaw instability causing three accidents, they failed to properly categorize and document the factors of the accidents.� The NTSB should have documented the CG and gross weight at the time of the accident, installation of yaw enhancements, geometry of the aileron installation that may have affected adverse yaw with aileron, slack in the rudder cables, and flaperon position.� This sort of data should also have been collected for all accidents where loss of control or failure to control was a factor.

The Challenger history has few accidents related to structural issues.� This record establishes the structural soundness of the Challenger design, especially considering it is always kit-built.

Although the reports suggest that poor airspeed control may be the major factor in loss of control accidents, there appears to be potential for improvement in lateral (roll) control.� My experience is that roll authority is just adequate at low speeds.� I have heard Challenger pilots recommend approach speeds of 60 mph or more, which is well beyond the usual 1.3 times stall speed that most aircraft use.� I think that downward flaperon deflection risks aileron stall at low speed.� The flaperon control should not be used for longitudinal trim, either.� Adoption of outboard part-span ailerons and elimination of symmetric aileron deflection would significantly improve the lateral control capability at low speeds, as well as stall performance of the wing (given a sharp trailing edge fairing).� Longitudinal trim should be through a conventional elevator trim tab.

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