Applicability: Model 7ECA, 7GCAA, 7GCBC, 8KCAB, and 8GCBC aircraft, that were manufactured before 12 August 2005; and have less than 250 hours time in service. Model 7AC, 7ACA, S7AC, 7BCM, 7CCM, S7CCM, 7DC, S7DC, 7EC, S7EC, 7ECA, 7FC, 7GC, 7GCA, 7GCAA, 7GCB, 7GCBA, 7GCBC, 7HC, 7JC, 7KC, 7KCAB, 8KCAB, and 8GCBC aircraft, that have installed, a flight control cable (or flight control cable included in a wing retrofit kit) that was purchased from American Champion Aircraft Corp. (ACAC) before 12 August 2005; and have less than 250 hours time in service since the above installation.

Requirement:

1. If the aircraft is to be operated before the time of the Requirement 2 inspection, accomplish the following:
a. Fabricate a warning placard, “Acrobatic Flight Prohibited”, with letters at least 1/8-inch in height, and install the placard in the cockpit in full view of the pilot; or,

b. Add the following statement to the Limitations Section of the Pilot’s Operating Handbook: “Acrobatic flight prohibited until the Requirement 3 inspection, and if necessary, Requirement 3 replacement, are accomplished”. This may be carried out by inserting a copy of this Directive into the Limitations Section of the Pilot’s Operating Handbook.

2. Inspect the Nicopress sleeves on the following flight control cables for the correct width in accordance with ACAC Service Letter No. 427 Revision B, dated 29 November 2005. Each sleeve has three swages or crimps and must not exceed a maximum width of 0.354 inches: Elevator cables in 6 locations; Rudder cables in 4 locations; Aileron cables in 12 locations; Flap cables in 6 locations.

3. Replace any flight control cable that has been found to have a Nicopress swage of incorrect width.

If Requirement 1 was accomplished, remove the temporary placard or POH limitation after accomplishment of Requirements 2 and 3 of this Directive.

If any flight control cable was found to have a Nicopress swage of incorrect width, within 10 days of inspection, report the findings to CASA e-mail address: airworthiness.directives@casa.gov.au

Note: FAA AD 2005-24-10 Amdt 39-14390 refers.

Compliance:

1. Before further flight after 23 January 2006.
2. Within 25 hours time in service after 23 January 2006.
3. Within 25 hours time in service after 23 January 2006.

This Airworthiness Directive becomes effective on 23 January 2006.

Background: The FAA received a report where, during a flight, the pilot of an ACAC Model 7KCAB aircraft noticed partial loss of aileron control and landed at the nearest airport. The Nicopress sleeve on the cable was incorrectly swaged, allowing the cable to slip within the sleeve. Incorrect swaging widths of the flight control cable Nicopress sleeves could result in the failure of the affected flight controls, and lead to loss of control of the aircraft.

FMI: www.casa.gov.au