
You can maintain your aircraft carefully and still have the unforeseen happen. On July 5th of this year I was on a flight back from Utah. I was over Taylor Park and starting to climb from 13,000 ft to 16,000 ft to climb over some clouds that were starting to build in the morning skies over the Grand Mesa and the Collegiate Peaks. As I pulled back to climb I heard a loud pop. I thought it had come from the tail but you can't see the tail well from the pilots seat. You can't pull over beside the road and check, so I went back to the business of flying the plane and donning oxygen for the higher altitudes at which I would be flying for a while. About twenty minutes later I landed safely in Salida at KANK the Salida airport where I base my Bellanca. Later, in inspection of the plane I found that one of the eight flying wires that support the tail had broken at the threaded area where it attaches to the vertical stabilizer. I was fortunate that only one had broken and that the other seven had continued to do their work, leaving the tail level and the controls free. After my mechanic and I had viewed the damage we came to the conclusion that since these wires were probably 40 years old, we should replace all eight flying wires. These wires can be seen in the picture in front of my hanger on this post page.
Here is where the internet becomes so valuable. I have gotten to view a number of opinions about how my flying wires were made and how they make them today. One thing that is different today is they "roll the threads" rather than "cut" them with a die, which may curtail a chance of a "stress riser" from the cutting. The FAA has no lift limit on these wires and that, plus input from the Bellanca engineer has lead us to a discussion on the tension settings may have been the culprit for the failure. It appears that the wires may have been too tight or not of equal tension. So I have taken to asking for opinions on what the tension settings should be. There is only a short terse one sentence description in the service manual. At Oshkosh this year, one wag suggested that since I was a musician I should tune them to B flat. At any rate we are currently carefully installing a new set of eight flying wires that were just manufactured in Scotland at Brunton's. We will have them equal in tension and I look forward to them lasting another 40 years, which "might" be longer than I will be flying this plane.
These older airplanes do take care, but in their simplicity they are a joy to work on and maintain. This Bellanca CruiseMaster returns the care with wonderful flying qualities.
Will by the River