AD 2005-24-10 Airworthiness Directives; American Champion Aircraft Corporation Models 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 Airplanes

Makes named: american champion, champion. Read the applicability below — it usually turns on serial or part numbers too.

(c) This AD affects the following airplane models, all serial numbers, that are certificated in any category: Models   (1) 7ECA, 7GCAA, 7GCBC, 8KCAB, and 8GCBC that: (i) were manufactured before August 12, 2005; and (ii) have less than 250 hours time-in-service (TIS). (2) 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 that: (i) 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 August 12, 2005; and (ii) have less than 250 hours TIS since the above installation.

(e) To address this problem, you must do the following:   Actions Compliance Procedures (1) If you operate the airplane before the inspection required in paragraph (e)(2) of this AD, do one of the following: (i) Fabricate (using letters at least 1/8 -inch in height) a warning placard with the following language and install this placard in the cockpit in full view of the pilot: “Acrobatic flight prohibited!”; or (ii) Add the following statement to the Limitations Section of the Pilots Operating Handbook (POH): “Acrobatic flight prohibited until the inspection and replacement requirements of AD 2005-24-10 are done.” To do this, you may insert a copy of this AD into the Limitations Section of the POH. Before further flight after January 17, 2006 (the effective date of this AD) No specific procedures are necessary for this action. The owner/operator holding at least a private pilot certificate as authorized by section 43.7 of the Federal Aviation Regulations (14 CFR 43.7) may do the placard or POH requirements. Make an entry into the aircraft records showing compliance with these portions of the AD in accordance with section 43.9 of the Federal Aviation Regulations (14 CFR 43.9). (2) Inspect the Nicopress sleeves on the following flight control cables for the correct width. Each sleeve has three swages or crimps and must not exceed a maximum width of 0.354 inches: Within 25 hours TIS after January 17, 2006 (the effective date of this AD) Follow ACAC Service Letter #427, Revision B, dated November 29, 2005. (i) Elevator cables in 6 locations; (ii) Rudder cables in 4 locations; (iii) Aileron cables in 12 locations; and (iv) Flap cables in 6 locations. (3) If you find any flight control cable Nicopress swages of incorrect width during the inspection required in paragraph (e)(2) of this AD, replace the affected cables Within 25 hours TIS after January 17, 2006 (the effective date of this AD) Follow ACAC Service Letter #427, Revision B, dated November 29, 2005. (4) If you performed the actions in paragraph (e)(1) of this AD, remove the temporary placard or POH limitation after completing the actions required in paragraphs (e)(2) and (e)(3) of this AD After completing the actions required in paragraphs (e)(2) and (e)(3) of this AD No specific procedures are necessary for this action. The owner/operator holding at least a private pilot certificate as authorized by section 43.7 of the Federal Aviation Regulations (14 CFR 43.7) may do the placard or POH requirements. Make an entry into the aircraft records showing compliance with these portions of the AD in accordance with section 43.9 of the Federal Aviation Regulations (14 CFR 43.9). (5) If you find any flight control cable Nicopress swages of incorrect width during the inspection required in paragraph (e)(2) of this AD, report the findings to FAA. The Office of Management and Budget (OMB) approved the information collection requirements contained in this regulation under the provisions of the Paperwork Reduction Act of 1980 (44 U.S.C. 3501 and those following sections) and assigned OMB Control Number 2120-0056 Within 10 days after the incorrect swage widths are found or within 10 days after January 17, 2006 (the effective date of this AD), whichever occurs later Include in your report the aircraft model, TIS of the flight control cable Nicopress swage, which cable swage was affected and its location, corrective action taken, and a point of contact name and phone number. Send your report to Wess Rouse, Small Airplane Project Manager, ACE-117C, Chicago Aircraft Certification Office, 2300 East Devon Avenue, Room 107, Des Plaines, Illinois 60018; facsimile: (847) 294-7834; e-mail: Wess.Rouse@faa.gov.

(d) This AD is the result of partial loss of aileron control because an incorrectly swaged cable sleeve allowed the cable to slip. We are issuing this AD to detect and correct incorrect swaging width of the flight control cable Nicopress sleeves, which could result in failure of the elevator, rudder, aileron, and flap controls. This failure could lead to loss of control of the airplane.