Van's Aircraft RV-6 - User Manual

14401 Keil Road NE, Aurora, Oregon, USA 97002
PHONE 503-678-6545 • FAX 503-678-6560
www.vansaircraft.com • info@vansaircraft.com
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SD-SB-SL Template R6.4 12/11/20 VAD-10009
SERVICE BULLETIN 99-06-01
Date Released: October 21, 2021
October 21, 2021 (Rev 2, made SB mandatory; removed
the original option for ongoing inspections)
June 30th, 1999 (Rev 1)
Date Effective: October 21, 2021
Subject: Overhead (“suspended”) rudder pedals for the RV-6 and
RV-6A are cracking and need to be replaced or
reinforcement gussets need to be installed
Affected Models: RV-6, RV-6A
Required Action: Replace or reenforce all affected WD-655-L/R rudder
pedals with gussets
Time of Compliance: Before further flight
Supersedes Notice: Revises and replaces SB 99-06-01 Rev 1
Labor Required: 6.0 Hours (Note this number is highly dependent on the
configuration of the RV-6, the presence of a center
console, or other unique features that may inhibit the
removal and subsequent installation of WD-655-L/R)
Level of Certification: Check the rules of the local controlling authority/agency
and the operating limitations for your aircraft
Synopsis:
There have been several cases of welds breaking on the overhead-style rudder pedals
(WD-655L and WD-655R) used in the RV-6/6A. These breaks usually occur where the
upright tubes from the pedal connect to the torque tube that runs across the fuselage.
The forward side of the torque tube fails in compression, allowing the aft side of the
torque tube to tear.
Van’s Aircraft, Inc. has static tested a set of production pedals and found they exceeded
the strength limits specified in FAR Part 23. However, since several operational failures
have occurred, corrective action should be taken.

Summary

Service Bulletin Synopsis

Service Bulletin Materials Required

Finger Patch Kit for Pedals

Kit containing eight finger patches for welding onto rudder pedals as per service bulletin.

Pedal Return for Modification Service

Option to return pedals to Van's for modification, requiring paint removal and specific marking.

Service Bulletin Method of Compliance

Gusset Installation Verification

Check for gussets on rudder pedals per Figure 1 and KAI drawing 43A.

Pedal Repair or Replacement Procedure

Remove affected pedals if no gussets are present, then repair or replace them as specified.

Post-Repair System Checks

Reinstall pedals and verify proper function of pedals, brake system, and related components.

Service Bulletin Documentation Requirements

Logbook Compliance Entry

Make a logbook entry indicating compliance per controlling authority requirements.

Maintenance Manual Addendum

Place a copy in the maintenance manual and add to the Addendum Documents List.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

This document is a Service Bulletin (SB 99-06-01) issued by Van's Aircraft, Inc., concerning a critical safety issue with the rudder pedals used in their RV-6 and RV-6A aircraft models. The bulletin, dated October 21, 2021, revises and replaces an earlier version (Rev 1 from June 30, 1999) and makes the corrective action mandatory.

Function Description:

The service bulletin addresses a structural integrity issue with the "overhead" or "suspended" style rudder pedals (part numbers WD-655-L/R) in RV-6 and RV-6A aircraft. These pedals are a fundamental control component, allowing the pilot to control the aircraft's yaw (left/right movement of the nose) and operate the wheel brakes. The issue specifically concerns cracking that occurs where the upright tubes of the pedal connect to the torque tube, which runs across the fuselage. This cracking is described as the forward side of the torque tube failing in compression, leading to tearing on the aft side. The primary function of this service bulletin is to ensure the continued safe operation of these aircraft by preventing catastrophic failure of the rudder pedals, which could lead to loss of control.

Important Technical Specifications:

• Affected Parts: WD-655-L/R rudder pedals (overhead/suspended style).
• Affected Aircraft Models: RV-6, RV-6A.
• Problem: Cracking and potential failure of welds where the pedal upright tubes connect to the fuselage torque tube.
• Corrective Actions:
  • Replacement of affected WD-655-L/R rudder pedals.
  • Reinforcement of affected WD-655-L/R rudder pedals with gussets.
• Reinforcement Kit: WD-655 FPKIT, which includes eight finger patches and instructions for welding.
• Compliance: Mandatory, "Before further flight."
• Static Testing: Van's Aircraft performed static tests on production pedals, which exceeded FAR Part 23 strength limits. However, operational failures necessitate this corrective action.
• Reference Drawings: KAI drawing 43A for pedal installation/removal and gusset detail.
• Gusset Detail: Figure 1 illustrates the gusset reinforcement, showing its placement on the firewall (front) side and pilot's (aft) side, specifically around the connection of the upright for the rudder pedal to the cross tube, including a "divot in front of rudder pedal upright."

Usage Features:

This service bulletin directly impacts the usability and safety of the RV-6 and RV-6A aircraft by ensuring the reliability of a critical flight control component. Pilots rely on the rudder pedals for directional control during taxi, takeoff, flight, and landing, as well as for braking. The described failure mode could lead to a loss of these essential controls, making the aircraft unsafe to operate. By mandating the inspection and repair/replacement of these pedals, the bulletin ensures that pilots can continue to use their aircraft with confidence in the integrity of the flight control system. The "Before further flight" compliance requirement emphasizes the immediate safety implications, meaning aircraft with unaddressed pedals should not be flown.

Maintenance Features:

The service bulletin outlines clear maintenance procedures and options for addressing the issue:

1. Inspection: Step 1 requires checking if rudder pedals already have gussets installed, referencing Figure 1 and KAI drawing 43A.
2. Removal: Step 2 instructs the removal of WD-655-L/R Rudder Pedals if no gussets are present, again referencing KAI drawing 43A.
3. Repair/Replacement Options (Step 3):
   • Self-Repair: Owners can obtain a free WD-655 FPKIT (finger patches) from Van's Aircraft and weld them onto the pedals.
   • Factory Modification: Pedals can be returned to Van's Aircraft for modification. Owners must remove paint around tubing intersections (approx. 4" in all directions from the joint) and mark the box "RMA-WD-655." This process is estimated to take 2-4 weeks.
   • New Part Replacement: Owners can purchase new WD-655-L/R parts at their own expense.
4. Installation: Step 4 details the reinstallation of the modified/new pedals per KAI drawing 43A.
5. Functional Check: Step 5 requires checking the proper function of the pedals, brake system, and any other affected systems after reinstallation.
6. Documentation: Step 6 mandates making a logbook entry to document compliance and placing a copy of the bulletin in the aircraft's maintenance manual, updating the Addendum Documents List.
7. Labor Estimate: The bulletin provides an estimated labor time of 6.0 hours, noting that this can vary significantly based on aircraft configuration (e.g., presence of a center console).
8. Ownership Transfer: Instructions are provided for owners no longer in possession of the aircraft to forward the information to the current owner/operator and notify Van's Aircraft via email (registrations@vansaircraft.com). Information on ownership transfer and registration is also provided via a URL.

This comprehensive approach ensures that the critical safety issue is addressed through various means, accommodating different owner capabilities and preferences, while maintaining strict compliance and documentation standards.

Van's Aircraft RV-6 Specifications

General

Brand	Van's Aircraft
Model	RV-6
Category	Music Pedal
Language	English