N407KH

Bell 407 None injury — A.L.E.R.T. KALISPELL REGIONAL MEDICAL CENTER INC.

ATA 5313

DURING A SCHEDULED INSPECTION A CRACKED ENGINE PAN WAS FOUND. THE CRACK WAS IN THE AREA OF THE AFT LEG OF THE RS, FWD BI-POD MOUNT. THE CRACK WAS EXTENDING FROM THE UPPER EDGE OF THE PAN AT FS 167.33, RBL 12.2, WL 70.57 WITH 2 LEGS OF THE CRACK RUNNING GENERALLY PARALLEL TO EACH OTHER WITH BOTH ARCING DOWN AND FWD APPROXIMATELY 2-3". FURTHER INVESTIGATION REVEALED RELATED CRACKS IN THE SUPPORTING LONGERON, BULKHEAD, STIFFENER, L-BRACKET, AND T-EXTRUSION CLIP. THE T-EXTRUSION PIECE USED TO TIE THE LONGERON TO THE BULKHEAD AT THIS LOCATION WAS BROKEN INTO 2 PIECES. THE PRESENCE OF SEALANT, PI-PODS AND SHIM PACKS AND OTHER ATTACHED MATERIAL, MADE THESE CRACKS VERY DIFFICULT TO DETECT UNTIL THE CRACKS HAD PROPOGATED INTO AN EXPOSED AREA. THE LIBERAL USE OF SEALANT ON THE INNER SURFACES OF THE STRUCTURE AT ASSEMBLY ALSO CONTRIBUTED TO CONCEALING THESE CRACKS. THE ACFT EXPERIENCED A HARD LANDING IN EARLY 2007 BUT HAS NO REPORTS OF SUDDEN STOPPAGE OR HARD LANDINGS IN RECENT HISTORY. IT IS BELIEVED FATIQUE STRESS AND THE REPORTED HARD LANDING MAY HAVE CONTRIBUTED TO THIS CRACKING PROBLEM.

ATA 5302

WHILE PERFORMING MX, A CRACK WAS DISCOVERED IN THE OUTER SKIN OF THE TAILBOOM ON THE LT SIDE AT THE FORWARD ROW OF RIVETS THAT SECURED THE TAIL ROTOR GEARBOX HOUSING. THE CRACK APPEARS TO HAVE STARTED AT ONE OF THE RIVETS, EXTENDED TO ANOTHER AND WAS CONTINUING ON PAST THE 2ND RIVET. THE CRACK WAS APPROX 1.5" IN LENGTH. PRODUCT SUPPORT WAS NOTIFIED AND THEY DETERMINED THAT THE CRACK MADE THE TAILBOOM UNSERVICABLE AND THAT THE UPPER SKIN WOULD HAVE TO BE REPLACED.