N198LT

HISTORY OF FLIGHTOn October 30, 2018, about 1448 eastern daylight time, an experimental amateur-built AutoGyro Cavalon gyroplane, N198LT, was destroyed during collision with a power pole, wires, terrain, a residence and a post-crash fire following a forced landing in Sebring, Florida. The commercial pilot and the pilot-rated passenger were fatally injured. Visual meteorological conditions prevailed, and no flight plan was filed for the flight which departed Sebring Regional Airport (SEF) about 1440 and was destined for Manatee Airport (48X), Palmetto, Florida. The personal flight was conducted under the provisions of 14 Code of Federal Regulations Part 91.

The purpose of the accident flight was for the pilot to take the passenger back to his home airport. Witnesses stated the pilot flew the accident gyroplane earlier in the day for about 2 hours, serviced it with fuel, then he and the passenger departed on the accident flight.

Radar information from the Federal Aviation Administration (FAA) revealed that a radar target identified as the accident gyroplane was acquired at 500 ft, and its track depicted a climb to about 1,000 ft and a cruise profile along a heading of about 280°. The radar track traversed the southern border of Lake Jackson in Sebring. About 1446, the radar data depicted that the gyroplane began a descent from about 1,000 ft over the southwestern shore of the lake. The descent followed the shoreline to the northwest, and the radar target disappeared at 900 ft, at which time the gyroplane's groundspeed was 90 knots and its ground track was about 0.4 mile southeast of the accident site. From where the descent began, a golf course was located about 25° and 0.5 mile to the left of the gyroplane's ground track.

SEF was not tower-controlled, but a commercial website that monitored the common traffic advisory frequency recorded a mayday call from the gyroplane at 1448. During the next 18 seconds, part of the gyroplane's registration number and a second mayday call were transmitted before the sounds associated with impact were heard. During the audible portions of the transmissions, sounds consistent with an engine increasing and decreasing in rpm were heard.

A witness who was driving southbound on the highway parallel to the shoreline of the lake stated that the gyroplane was traveling northwest about 300 ft above ground level "with very little airspeed" and appeared to be turning to the east. The gyroplane then "entered an autorotation," and, when it had descended to about 150 ft, "the nose of the aircraft dropped immediately turning toward [the] east then back toward the north." The gyroplane descended from the witness's view; afterward, he saw a large fireball. PERSONNEL INFORMATIONThe pilot held a commercial pilot certificate with a rating for rotorcraft-gyroplane. He held a private pilot certificate with ratings for airplane single engine land and instrument airplane. His most-recent FAA 2nd class medical certificate was issued August 25, 2017. A review of the pilot's FAA Examiner Designation and Qualification Record revealed he had accrued 4,010 total hours of flight experience, 2,715 hours of which were in "rotortype" aircraft. AIRCRAFT INFORMATIONAccording to FAA records, the gyroplane's airworthiness certificate was issued August 17, 2017. Airframe logbooks were not recovered, but photographs of maintenance entries revealed the most recent condition inspection was completed October 4, 2018 at 16.6 total aircraft hours.

Postaccident interviews, e-mails, and collected documents revealed that the owner/builder purchased the gyroplane kit from the German kit manufacturer through AutoGyro USA, Stevensville, Maryland, along with a "build-assist" agreement with Cloud9 Helicopters, West Palm Beach, Florida, an independent dealer of AutoGyro USA products. The owner/builder had no experience building or flying aircraft of any kind. His intention was to build the gyroplane and then learn to fly it. Cloud9 Helicopters agreed to perform the build-assist in exchange for 75 flight hours in the completed gyroplane in order to demonstrate the product to prospective customers for future sales.

After an experienced factory mechanic could not be arranged by the CEO of AutoGyro USA, Cloud9 Helicopters employed a mechanic who had not previously assembled an AutoGyro product, which conservatively required 3 weeks for assembly by an experienced builder. Later, an experienced AutoGyro builder, who could provide only one week's help was brought in to temporarily assist with building efforts. Upon arrival, the experienced builder directed that the gyroplane be disassembled because components had been installed incorrectly and in the wrong sequence. He found all the parts, components, and hardware had arrived with the kit, but they were packaged haphazardly, and considerable time was expended as the contents of the boxes were inventoried and organized for assembly. Further, common consumables (adhesives, lubricants, etc.) were not on hand and had to be purchased. According to the owner/builder, he "spent a lot of time going to Home Depot." When asked about his involvement with the construction of the gyroplane he said, "I put on stickers and wheel covers, nothing critical."

After the airworthiness certificate was issued, the gyroplane was test flown for the phase one testing period (40 hours). The test pilot hired to complete the flight testing stated that the test plan was modeled after FAA Advisory Circular 90-89A, Amateur-Built Aircraft and Ultralight Flight Testing Handbook. As part of the plan, the test pilot performed engine run-ups, system checks (pre-rotator, etc), high-speed taxi tests and short "hops" over the runway about 20 ft above the ground. The test pilot stated that during the testing the cyclic control exhibited a "sharp left pull" and that he explained the issue to maintenance personnel. The test pilot also stated that multiple exchanges with maintenance personnel and AutoGyro USA failed to resolve the issue. The test pilot further stated that he "grounded" the gyroplane at that time due to "improperly rigged flight controls" and indicated that he would not fly the gyroplane again until it was fixed. At the time that the test pilot ceased the test plan, the gyroplane had accrued 16.6 hours.

According to the owner/builder, the CEO of AutoGyro USA and the president of Cloud9 Helicopters were "not available" in the months following to complete the fly-off. In March 2018, the CEO of AutoGyro USA resigned his position and went to work for a competing gyroplane manufacturer, and Cloud9 helicopters became an independent dealer for the same manufacturer. Cloud9 Helicopters no longer had incentive to complete the project and the owner/builder had lost interest, so in September 2018, the owner/builder contacted AutoGyro USA to broker the sale of his gyroplane. Cloud9 Helicopters agreed to complete the condition inspection and the phase one flight testing in advance of an airshow that began November 1, 2018. At the time the agreement was made, which was on or about September 18th, 2018, the gyroplane had not accrued any additional flight hours since the previous flight testing had ceased. According to the President of Cloud9 Helicopters, he and 3 other pilots completed the flight tests between October 4 and 29, 2018.

On October 29, 2018, the accident pilot, who was the chief operating officer for AutoGyro USA, took possession of the gyroplane from Cloud9 Helicopters. His inspection of the accident gyroplane and its logbooks revealed that the hobbs meter displayed exactly 40.0 hours, the carburetors leaked, and completion of the 40-hour flight test period had not been documented in the maintenance logs. The president of Cloud9 Helicopters then made the log entry and added that the gyroplane "needed a rotor balance." The pilot then pointed out the carburetor leaks to the mechanic who had assisted with the build and completed the most recent condition inspection. The mechanic went for tools to address the leaks and returned to find the pilot had departed in the gyroplane.

The accident pilot then flew the gyroplane from North Palm Beach County Airport (F45), West Palm Beach, Florida to SEF. During the flight, the pilot noted that the cyclic control vibration was "excessive," and the airspeed indicator was inoperative. In text messages to the president of AutoGyro USA, the pilot stated, "…carbs leaking fuel, airspeed indicator not working, [and] can mix eggs with this control stick," and "I see how roughly this was put together." The accident pilot attached a video to the message to showing the control stick shaking during the flight. The president of AutoGyro USA stated that, after landing, the pilot and a colleague examined the gyroplane and found the airspeed indicator "disconnected." They retorqued the carburetor float bowls, and "wondered if the 40 hours Phase 1 testing had been done." The two further attempted to balance the rotor system through trial and error by adding and then subtracting weight on either side of the rotor head, which was unsuccessful on each attempt and subsequent test flights. AutoGyro USA offered to ship the necessary rotor balancing equipment to the accident pilot, who rejected the idea.

The AutoGyro Cavalon build and assembly instructions, the 25- and100-hour condition inspection checklists, the maintenance manual instruction, and the AutoGyro Pilot Operating Handbook provide instructions for inspection of the flight control connections. METEOROLOGICAL INFORMATIONAt 1515, the weather recorded at SEF included clear skies, 10 statute miles visibility, and winds from 030 degrees at 6 knots. The temperature was 28°C, and the dew point was 13°C. The altimeter setting was 30.07 inches of mercury. AIRPORT INFORMATIONAccording to FAA records, the gyroplane's airworthiness certificate was issued August 17, 2017. Airframe logbooks were not recovered, but photographs of maintenance ent...