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Australian Ultralight Federation Inc
ARBN 070 931 645U35/59
Wollongong St PO Box 1265,
Fyshwick ACT 2609
Ph: 02 6280 4700
Fax: 02 6280 4775
Email: tech@auf.asn.au
Issue 2: 19 October 2001
Issue 1: 16 October 2001
ULTRALIGHT AIRCRAFT AIRWORTHINESS NOTICE-AIRWORTHINESS NOTICE IDENTIFICATION NUMBER 1- 2001 Issue 2
WARP DRIVE PROPELLERS – DIRECT DRIVE
APPLICATIONS HUB CRACKING
(JABIRU ENGINE FITMENT IN PARTICULAR)
To:
Owners/Operators of all AUF Aircraft fitted direct drive engines
employing Warp Drive Propellers
Background:
The AUF has been advised by Thruster UK of
cracking found in 6 hubs and in the aluminium roots of two blades
of Warp Drive propellers of aircraft fitted with Jabiru engines.
Initially, Thruster in the UK raised a
Mandatory Service Bulletin No TAS/SB07 requiring that All Thruster
aircraft fitted with Jabiru 2200A engines be visually checked
before each flight and that they should not be flown with that
propeller if any cracking is found. The matter was referred to The
UK CAA who issued a Mandatory directive requiring compliance with
the Thruster UK Bulletin.
The latest advice (and reason for issue 2) is
that the UK CAA has now grounded all Jabiru/Warp Drive Vision
aircraft until approved corrective action has been incorporated
because all cracks are not visible to the unaided eye, their
detection requiring non-destructive techniques.
As at 19 Oct, the final solution is understood
to be a replacement hub based on the hub for O-200 Engines.
Because this appears to be an engine/propeller
combination problem, the AUF considers that all aircraft fitted
with a Jabiru/Warp Drive combination should be inspected. The
problem reported by Thruster UK is on 2 bladed propellers fitted
to Jabiru Engines only, but a one off inspection of two or three
bladed warp drive propellers fitted to other direct drive engines
would appear to be prudent also. Records show there are 4 Visions,
a Carlson Sparrow and a Zenair STOL fitted with the Warp
 Drive/Jabiru combination.
Note that the Jabiru Engine is only supported
by the manufacturer when fitted propellers manufactured by Jabiru
itself.
Action Required:
Effective 19 October, upon receipt of this
notice:
A. On aircraft fitted with Jabiru
Engines incorporating Warp Drive Propellers:
- Propellers with a total time of 50 hours or more are to be
removed from service and are not to be reused without
engineering clearance.
- For propellers with less than 50 hours, the aluminium hub
and blade roots of the Warp Drive
 propellers are to be visually
checked for cracking before the next flight and before each
successive flight until removal at 50 hours.
- Before next flight, all propellers are to be checked for
correct torqueing in accordance with manufacturer’s
specifications.
- If there is any sign of cracking, the propeller is to be
withdrawn from service before further flight and the AUF advised
of the nature of cracking, the engine/propeller combination and
the cumulative time in service of the propeller on that and any
other engines to which it may have been fitted.
- The initial inspection and any findings are to be recorded
in the Aircraft Log Book quoting this Airworthiness Notice AN
1-2001
B. On all other aircraft with direct
drive engines fitted with any type of Warp Drive Propeller:
- Before the next flight, the aluminium hub and blade roots
are to be visually checked for cracking.
- All Propellers are to be checked for correct torqueing in
accordance with manufacturer’s specifications.
- Warp Drive propellers which may have been fitted to
Jabiru Engines at any stage of their lives are to be
inspected for cracking at each DAILY inspection as required by
para 1 above pending
 closure of the problem.
- If there is any sign of cracking, the propeller is to be
withdrawn from service before further flight and the AUF advised
of the nature of cracking, the engine/propeller combination and
the cumulative time in service of the propeller on that and any
other engines to which it may have been fitted.
- The initial inspection and any findings are to be recorded
in the Aircraft Log Book quoting this Airworthiness Notice AN
1-2001
Reports Required:
If any indication of cracking is found, the AUF
is to be advised of the:
- nature of cracking;
- details of the engine/propeller combination; and
- cumulative time in service of the propeller on the current
engine and on any other engines to which it may have been
fitted.
R Hewitt-Cook
Technical Manager
Defect Reporting is one of the primary ways we
have in ensuring continued safety in our operations.
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