assembly interruption a dangerous thing

On May 22, 7:51 pm, CLewis95 wrote:
On May 22, 12:43 pm, danlj wrote:



Dear List,

From time to time a pilot is broken or totalled because assembly was
in some way incomplete. I'm simply writing to remind us all not to
permit ourselves to be involved in conversation, however well-
intended, during assembly.

This is motivated by the fact that I discovered that the wing root
tape IS sufficient to hold the right wing onto a Ventus when the main
spar pin is not fully engaged. This discovery was sufficiently
humiliating that I have waited for a few days to confess.

The hookups of the Ventus are brain-dead simple and foolproof, except
that the locking pins really do need to be engaged.

Sometimes I have forgotten to pull off the wing-root tape before
trying to remove the wings during disassembly, which has sparked one
of those random fantastical thoughts, "I wonder if the main spar pin
is really needed."

I normally assemble completely alone; one day last week a friend came
along to see the glider and wanted to 'help' assemble, and of course
happens to be one of those wonderfully friendly, fascinating, chatty
types.

During the latter part of the subsequent 2-hour flight, I heard a
faint low rumble from behind, making me wonder if the engine
compartment doors had fully closed.

After I landed, I discovered that the tape over the right wing root
gap was still fully covering the gap, but the gap had widened from the
usual 2mm to about 5 mm. I need hardly tell you the sense of fright
and self-abasement this inspired.

I immediately realized that I had failed to push the main spar pin
'home' - normally the sequence is to put it halfway through (into the
left spar) to hold the left wing in place while the right wing is
installed, then go straightaway and push it home. In this case an
interruption to correct wing-taping being done by my 'assistant'
caused this step to be skipped.

I recall an old suggestion that pilots should wear a red cap as a
signal not to be interrupted. But the signal won't be obeyed until
it's learned. Maybe a more effective device would be to screen-print
words on the front and back of a light vest to be worn during
assembly, perhaps
"DEAF" - or
"Shut up (please)"

But of course the real discipline is with us assemblers, to not permit
interruptions, and to say to the first person who offers to help,
"Yes, you can help by preventing anyone from talking to me until this
is done."

Dan Johnson

Thanks for sharing this Dan.

I love your simple answer to the eager helpers.... "you can help by
preventing anyone from talking to me until this is done." After a
while the eager helpers will get the idea.

Curt Lewis - 95

We had a very talkative visitor show up at our club the other day, who
approached one pilot in the middle of
assembling his plane. The pilot just turned to the fellow and said,
"I am doing things that my life depends on
me doing correctly. I'll talk to you later."

Addition to safety concerns is "rash". My last glider fuselage
received an ugly scratch when a veteran glider pilot insisted on
getting my attention to tell me "you should have been here yesterday".
I ignored him, but he kept repeating himself, so I rolled the wing
back into the trailer to wait him out, dragging the wing cradle bolt
along the fuselage as I did so. I was not pleased.

On 23 May, 00:51, CLewis95 wrote:

I love your simple answer to the eager helpers.... "you can help by
preventing anyone from talking to me until this is done." *After a
while the eager helpers will get the idea.

I like having eager helpers. I can't lift a Pirat centre section on my
own, and I can say to them "Will you confirm that this control is on
tight and that a small pin has popped out behind it?"

Ian

I was always taught that if you're interupted in any check list type
of activity to go back to the beginning and start over until you get
to a proper finish. If it is already assembled, you just need to check
that it is complete and correct.

My flying group is a very talkative and helpful group so we often
interupted in assembly or disassembly, so this technique works quite
well.

Also on our 1-26's only the pilot installs and fastens the Turtle deck
so he can check that all 10 pins are installed and locked before
flight.

JayWalker

Uh, that is scary... I've wondered several times while helping to put
together Schempp-Hirth planes, why the heck they've done the wing assembly
the way the have - right, it's easy to do it that way, the wings just sit
there when put into the body, but some day someone would forget the main
spar pin... I think it would be a good idea to always (well, only when the
wings aren't mounted!) let the main spar pin rest on the plane's pilot seat
(back seat on two-seater isn't good enough if it's flown by one person.

A couple of days ago, the danish news paper Politiken brought this very
relevant cartoon: http://politiken.dk/wm/article508875.ece - the text says:
"Erik, I told you to get those wings checked before we went on vacation".


Best regards,

Morten Wartou

"danlj" skrev i meddelelsen
...
Dear List,

From time to time a pilot is broken or totalled because assembly was
in some way incomplete. I'm simply writing to remind us all not to
permit ourselves to be involved in conversation, however well-
intended, during assembly.

This is motivated by the fact that I discovered that the wing root
tape IS sufficient to hold the right wing onto a Ventus when the main
spar pin is not fully engaged. This discovery was sufficiently
humiliating that I have waited for a few days to confess.

The hookups of the Ventus are brain-dead simple and foolproof, except
that the locking pins really do need to be engaged.

Sometimes I have forgotten to pull off the wing-root tape before
trying to remove the wings during disassembly, which has sparked one
of those random fantastical thoughts, "I wonder if the main spar pin
is really needed."

I normally assemble completely alone; one day last week a friend came
along to see the glider and wanted to 'help' assemble, and of course
happens to be one of those wonderfully friendly, fascinating, chatty
types.

During the latter part of the subsequent 2-hour flight, I heard a
faint low rumble from behind, making me wonder if the engine
compartment doors had fully closed.

After I landed, I discovered that the tape over the right wing root
gap was still fully covering the gap, but the gap had widened from the
usual 2mm to about 5 mm. I need hardly tell you the sense of fright
and self-abasement this inspired.

I immediately realized that I had failed to push the main spar pin
'home' - normally the sequence is to put it halfway through (into the
left spar) to hold the left wing in place while the right wing is
installed, then go straightaway and push it home. In this case an
interruption to correct wing-taping being done by my 'assistant'
caused this step to be skipped.

I recall an old suggestion that pilots should wear a red cap as a
signal not to be interrupted. But the signal won't be obeyed until
it's learned. Maybe a more effective device would be to screen-print
words on the front and back of a light vest to be worn during
assembly, perhaps
"DEAF" - or
"Shut up (please)"

But of course the real discipline is with us assemblers, to not permit
interruptions, and to say to the first person who offers to help,
"Yes, you can help by preventing anyone from talking to me until this
is done."

Dan Johnson

On May 22, 1:43*pm, danlj wrote:
Dear List,

From time to time a pilot is broken or totalled because assembly was
in some way incomplete. I'm simply writing to remind us all not to
permit ourselves to be involved in conversation, however well-
intended, during assembly.

This is motivated by the fact that I discovered that the wing root
tape IS sufficient to hold the right wing onto a Ventus when the main
spar pin is not fully engaged. This discovery was sufficiently
humiliating that I have waited for a few days to confess.

The hookups of the Ventus are brain-dead simple and foolproof, except
that the locking pins really do need to be engaged.

Sometimes I have forgotten to pull off the wing-root tape before
trying to remove the wings during disassembly, which has sparked one
of those random fantastical thoughts, "I wonder if the main spar pin
is really needed."

I normally assemble completely alone; one day last week a friend came
along to see the glider and wanted to 'help' assemble, and of course
happens to be one of those wonderfully friendly, fascinating, chatty
types.

During the latter part of the subsequent 2-hour flight, I heard a
faint low rumble from behind, making me wonder if the engine
compartment doors had fully closed.

After I landed, I discovered that the tape over the right wing root
gap was still fully covering the gap, but the gap had widened from the
usual 2mm to about 5 mm. I need hardly tell you the sense of fright
and self-abasement this inspired.

I immediately realized that I had failed to push the main spar pin
'home' - normally the sequence is to put it halfway through (into the
left spar) to hold the left wing in place while the right wing is
installed, then go straightaway and push it home. In this case an
interruption to correct wing-taping being done by my 'assistant'
caused this step to be skipped.

I recall an old suggestion that pilots should wear a red cap as a
signal not to be interrupted. But the signal won't be obeyed until
it's learned. Maybe a more effective device would be to screen-print
words on the front and back of a light vest to be worn during
assembly, perhaps
*"DEAF" - or
"Shut up (please)"

But of course the real discipline is with us assemblers, to not permit
interruptions, and to say to the first person who offers to help,
"Yes, you can help by preventing anyone from talking to me until this
is done."

Dan Johnson

I use a written assembly check list, laminated and attached to a
clipboard. I check off each step with a red grease pencil. If by
chance I'm interrupted, I have a written record of the assembly
progress and know exactly where I left off and what steps remain.

Rich Kiray

On May 23, 8:53�am, wrote:
On May 22, 1:43�pm, danlj wrote:





Dear List,

From time to time a pilot is broken or totalled because assembly was
in some way incomplete. I'm simply writing to remind us all not to
permit ourselves to be involved in conversation, however well-
intended, during assembly.

This is motivated by the fact that I discovered that the wing root
tape IS sufficient to hold the right wing onto a Ventus when the main
spar pin is not fully engaged. This discovery was sufficiently
humiliating that I have waited for a few days to confess.

The hookups of the Ventus are brain-dead simple and foolproof, except
that the locking pins really do need to be engaged.

Sometimes I have forgotten to pull off the wing-root tape before
trying to remove the wings during disassembly, which has sparked one
of those random fantastical thoughts, "I wonder if the main spar pin
is really needed."

I normally assemble completely alone; one day last week a friend came
along to see the glider and wanted to 'help' assemble, and of course
happens to be one of those wonderfully friendly, fascinating, chatty
types.

During the latter part of the subsequent 2-hour flight, I heard a
faint low rumble from behind, making me wonder if the engine
compartment doors had fully closed.

After I landed, I discovered that the tape over the right wing root
gap was still fully covering the gap, but the gap had widened from the
usual 2mm to about 5 mm. I need hardly tell you the sense of fright
and self-abasement this inspired.

I immediately realized that I had failed to push the main spar pin
'home' - normally the sequence is to put it halfway through (into the
left spar) to hold the left wing in place while the right wing is
installed, then go straightaway and push it home. In this case an
interruption to correct wing-taping being done by my 'assistant'
caused this step to be skipped.

I recall an old suggestion that pilots should wear a red cap as a
signal not to be interrupted. But the signal won't be obeyed until
it's learned. Maybe a more effective device would be to screen-print
words on the front and back of a light vest to be worn during
assembly, perhaps
�"DEAF" - or
"Shut up (please)"

But of course the real discipline is with us assemblers, to not permit
interruptions, and to say to the first person who offers to help,
"Yes, you can help by preventing anyone from talking to me until this
is done."

Dan Johnson

I use a written assembly check list, laminated and attached to a
clipboard. I check off each step with a red grease pencil. �If by
chance I'm interrupted, I have a written record of the assembly
progress and know exactly where I left off and what steps remain.

Rich Kiray- Hide quoted text -

- Show quoted text -

On May 23, 8:53�am, wrote:
On May 22, 1:43�pm, danlj wrote:





Dear List,

From time to time a pilot is broken or totalled because assembly was
in some way incomplete. I'm simply writing to remind us all not to
permit ourselves to be involved in conversation, however well-
intended, during assembly.

This is motivated by the fact that I discovered that the wing root
tape IS sufficient to hold the right wing onto a Ventus when the main
spar pin is not fully engaged. This discovery was sufficiently
humiliating that I have waited for a few days to confess.

The hookups of the Ventus are brain-dead simple and foolproof, except
that the locking pins really do need to be engaged.

Sometimes I have forgotten to pull off the wing-root tape before
trying to remove the wings during disassembly, which has sparked one
of those random fantastical thoughts, "I wonder if the main spar pin
is really needed."

I normally assemble completely alone; one day last week a friend came
along to see the glider and wanted to 'help' assemble, and of course
happens to be one of those wonderfully friendly, fascinating, chatty
types.

During the latter part of the subsequent 2-hour flight, I heard a
faint low rumble from behind, making me wonder if the engine
compartment doors had fully closed.

After I landed, I discovered that the tape over the right wing root
gap was still fully covering the gap, but the gap had widened from the
usual 2mm to about 5 mm. I need hardly tell you the sense of fright
and self-abasement this inspired.

I immediately realized that I had failed to push the main spar pin
'home' - normally the sequence is to put it halfway through (into the
left spar) to hold the left wing in place while the right wing is
installed, then go straightaway and push it home. In this case an
interruption to correct wing-taping being done by my 'assistant'
caused this step to be skipped.

I recall an old suggestion that pilots should wear a red cap as a
signal not to be interrupted. But the signal won't be obeyed until
it's learned. Maybe a more effective device would be to screen-print
words on the front and back of a light vest to be worn during
assembly, perhaps
�"DEAF" - or
"Shut up (please)"

But of course the real discipline is with us assemblers, to not permit
interruptions, and to say to the first person who offers to help,
"Yes, you can help by preventing anyone from talking to me until this
is done."

Dan Johnson

I use a written assembly check list, laminated and attached to a
clipboard. I check off each step with a red grease pencil. �If by
chance I'm interrupted, I have a written record of the assembly
progress and know exactly where I left off and what steps remain.

Rich Kiray- Hide quoted text -

- Show quoted text -

One thing I did when I owned my Ventus was I would clip the main
safety pin on the boom mike. You shouldn't be taking off if that
thing was hanging in front of your face!

I use a written assembly check list, laminated and attached to a
clipboard. I check off each step with a red grease pencil. *If by
chance I'm interrupted, I have a written record of the assembly
progress and know exactly where I left off and what steps remain.

Rich Kiray-

I like this approach. As I've noted here before, I have a written
checklist, two columns of items in various stages from "assembly" to
"grid" to "pre-launch", with a separate section for contest-specific
items (task sheet, retrieve number, etc.). They're organized so I can
start in the wing carrythrough area then move to the instruments then
under the fuselage to the right wing, tail, left wing., etc. I shared
it with ex F-14 Navy pilot Bif Huss in Cordele last week and he had
some good suggestions from his own checklists based on military pilot
practices. I'm waiting to get his consolidated version back.
Checklists are deceptively simple stuff but there are so many things
that have to be attended to before we fly that I haven't trusted my
memory in many years.

During a contest, I actually check each item off: a vertical mark one
day, then a horizontal mark the next, a circle the next, etc. (uses
less paper that way; a laminated card and grease pencil would be
better, but I keep adding to the checklist). Just so I can see at a
glance what I've missed. That gives me the comfort of stopping in the
middle of the sequence to do something else (including chatting) or
skipping past an item knowing I'll see it later and come back to it.
For local flights, I'm more inclined to eyeball each item. Every
glider is different and pilots have different requiremnents, but
here's my list in plain text format. Please post your additions/
comments. It's been a while since we did this on RAS.

Chip Bearden
ASW 24 "JB"
USA

ASSEMBLY ( * Critical Assembly Check)
___ * Main Pins Safetied
___ ELT Armed
___ Main Battery Installed/Checked
___ Tail Battery Installed/Checked
___ Radio Checked
___ LNAV Checked
___ GPS-NAV Installed/Checked
___ Pocket NAV Installed w/ Flash Card
___ Garmin GPS Receiver Installed/Cleared
___ Extra Batteries
___ Altimeter Set
___ Drinking Water Loaded
___ Parachute/Lumbar Cushion In
___ Relief System OK
___ Tire Pressure 35 psi
___ Landing Gear Doors/Springs OK
___ Tow Release Checked
___ Left Wing: Wing Root Taped
___ * Winglet Installed
___ Zig-zag Tape OK
___ Mylar Seals OK
___ Aileron Drive OK
___ Rear Static Ports Clear
___ Multi Probe Installed
___ * Tail Bolt Installed
___ Tail Taped
___ Tail Wheel 35 psi
___ Elevator/Rudder: Mylar Seals OK
___ Zig-zag Tape OK
___ Rudder Cable Attachments OK
___ Right Wing: Zig-zag Tape OK
___ Mylar Seals OK
___ Aileron Drive OK
___ * Winglet Installed
___ Wing Root Taped
___ Wings Washed
___ Fuselage/Tail Washed
___ Canopy Clean
___ Water Ballast Filled/Valves OK
___ Oxygen Bottle Filled/Installed
___ Oxygen Canula Installed

GRID
___ Sunglasses (dark)
___ Sunglasses (light)
___ Glasses
___ Glasses - Reading
___ Map
___ Food
___ External Catheter
___ Cell Phone
___ Hat
___ Wallet Stowed in Cockpit
___ Final Glide Calculator
___ Pencil/Pen
___ Cleaning Cloth
___ Flying Glove
___ Flying Clothes/Boots
___ Landout Jacket Stowed
___ Telephone Coins
___ Tie Down Stakes/Ropes
___ TOST Adapter/Rope
___ Survival Kit & Flashlight

TASK CHECK
___ Task Sheet
___ Turnpoint List
___ Radio Frequencies Stored in Radio Memory
___ Landing Card with Contest Phone Number
___ Map (with course marked)
Pocket NAV
___ Altitude set
___ Task set

PRE TAKEOFF
___ * POSITIVE CONTROL CHECK
___ Tail Dolly Off
___ Radio On
___ LNAV/GPS-NAV On
___ Pocket NAV On
___ Garmin GPS On
___ Wind Direction Checked
___ Air Vents Adjusted
___ Oxygen: Connected/Valve Open

IN COCKPIT
___ Altimeter Set
___ Belts Fastened
___ Cable
___ Controls Checked Positively
___ Canopy Down and Locked
___ Dive Brakes Closed and Locked
(Dive Brakes Out for Takeoff)

_______________________________

LANDOUT
___ GPS-NAV trace transferred
___ LNAV/GPS-NAV/Pocket NAV Off
___ Pocket NAV in pocket
___ Garmin GPS in pocket
___ ELT Off
___ Wallet In Pocket
___ Lat./Long.
___ Retrieve Telephone Number
___ Cell Phone in Pocket
___ Glider Secured
___ Static Ports Taped (loosely!)
___ Multi Probe Stowed/Port Taped
___ Landing Card Filled Out
___ Retrieve Directions
___ REMOVE PROBE/PORT TAPE

TRAILER HOOK UP
___ Wingstands Loaded
___ Top Latched and Safetied
___ Tie Down Ropes Removed
___ Front Door Latched Securely
___ Hitch Locked on 2" (NOT 1 7/8") Ball/Checked
___ Dolly Wheel Stowed
___ Safety Chain Connected
___ Breakaway Wire Connected
___ Lights Connected and Checked
___ HAND BRAKE OFF ! ! !
___ Tires OK
___ Watch Out For Tie Down Stakes !