{"id":"F2006L00209","name":"AD/CHA/29 - Flight Control Cables","slug":"ad-cha-29-flight-control-cables","collection":"legislative_instrument","jurisdiction":"commonwealth","status":"in_force","isInForce":true,"actNumber":null,"makingDate":null,"administeringDepartment":null,"currentVersion":{"id":58157,"registerId":"commonwealth-F2006L00209-current","compilationNumber":null,"startDate":"2026-04-02","status":"InForce","reasons":null,"registeredAt":null},"sections":[{"sectionNumber":"American Champion (Aeronca, Bellanca) Se","sectionType":"division","heading":"American Champion (Aeronca, Bellanca) Series Aeroplanes","content":"### American Champion (Aeronca, Bellanca) Series Aeroplanes\n\n| AD/CHA/29 | Flight Control Cables | 3/2006 DM |\n| --------- | --------------------- | --------- |\n\n| Applicability: | Model 7ECA, 7GCAA, 7GCBC, 8KCAB, and 8GCBC aircraft, that were manufactured before 12 August 2005; and have less than 250 hours time in service.Model 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 aircraft, that 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 12 August 2005; and have less than 250 hours time in service since the above installation.                                                                                                                                                                                                                                                                                                                                                                                                                                                                  |\n| -------------- | ---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Requirement:   | 1. If the aircraft is to be operated before the time of the Requirement 2 inspection, accomplish the following:a. Fabricate a warning placard, “Acrobatic Flight Prohibited”, with letters at least 1/8-inch in height, and install the placard in the cockpit in full view of the pilot; or,b. Add the following statement to the Limitations Section of the Pilot’s Operating Handbook: “Acrobatic flight prohibited until the Requirement 3 inspection, and if necessary, Requirement 3 replacement, are accomplished”. This may be carried out by inserting a copy of this Directive into the Limitations Section of the Pilot’s Operating Handbook.2. Inspect the Nicopress sleeves on the following flight control cables for the correct width in accordance with ACAC Service Letter No. 427 Revision B, dated 29 November 2005. Each sleeve has three swages or crimps and must not exceed a maximum width of 0.354 inches:Elevator cables in 6 locations;Rudder cables in 4 locations;Aileron cables in 12 locations;Flap cables in 6 locations. |\n\n|             | 3. Replace any flight control cable that has been found to have a Nicopress swage of incorrect width.If Requirement 1 was accomplished, remove the temporary placard or POH limitation after accomplishment of Requirements 2 and 3 of this Directive.If any flight control cable was found to have a Nicopress swage of incorrect width, within 10 days of inspection, report the findings to CASA e-mail address: airworthiness.directives@casa.gov.auNote: FAA AD 2005-24-10 Amdt 39-14390 refers. |\n| ----------- | ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- |\n| Compliance: | 1. Before further flight after 23 January 2006.2. Within 25 hours time in service after 23 January 2006.3. Within 25 hours time in service after 23 January 2006.                                                                                                                                                                                                                                                                                                                                     |\n|             | This Airworthiness Directive becomes effective on 23 January 2006.                                                                                                                                                                                                                                                                                                                                                                                                                                    |\n| Background: | The FAA received a report where, during a flight, the pilot of an ACAC Model 7KCAB aircraft noticed partial loss of aileron control and landed at the nearest airport. The Nicopress sleeve on the cable was incorrectly swaged, allowing the cable to slip within the sleeve. Incorrect swaging widths of the flight control cable Nicopress sleeves could result in the failure of the affected flight controls, and lead to loss of control of the aircraft.                                       |\n\n![](image.001.png)  \nJames Coyne  \nDelegate of the Civil Aviation Safety Authority\n\n19 January 2006","sortOrder":0},{"sectionNumber":"AD/CHA/29","sectionType":"part","heading":"AD/CHA/29","content":"## AD/CHA/29","sortOrder":1},{"sectionNumber":"Flight Control Cables","sectionType":"part","heading":"Flight Control Cables","content":"## Flight Control Cables","sortOrder":2},{"sectionNumber":"3/2006 DM","sectionType":"part","heading":"3/2006 DM","content":"## 3/2006 DM","sortOrder":3}],"analysis":{"flash_summary_failed":{"failed":true,"reason":"A positive credit balance is required for all requests, including BYOK, so fallback providers remain available. Add credits at https://vercel.com/d?to=%2F%5Bteam%5D%2F%7E%2Fai%3Fmodal%3Dtop-up to continue.","source":"analysis-cron"},"flash_summary":{"complexity_score":5,"scope_assessment":{"changed":false,"description":"The directive applies only to listed American Champion models and to flight control cables purchased from ACAC before 12 August 2005 with <250 hours since installation. There is no textual indication this instrument broadens or narrows that applicability compared to the referenced FAA AD; it confines obligations to affected aircraft owners/operators (inspection, replacement, reporting) to address the specific risk of incorrect Nicopress swaging."},"complexity_factors":["Multiple layered applicability criteria: specific aircraft models, manufacture/purchase date (before 12 Aug 2005) and <250 hours time-in-service since installation","Precise technical inspection threshold: Nicopress swage must not exceed 0.354 inches","Numerous inspection locations (elevator 6, rudder 4, aileron 12, flap 6 = 28 swages) increasing labour time and error risk","Short, staggered compliance timeframes (some actions ‘before further flight’, others within 25 hours time-in-service)","Temporary operational restriction option (fabricate/fit placard or add POH limitation) until inspection/replacement is done","Replacement obligation if out-of-tolerance and a 10‑day mandatory reporting requirement to CASA when defects found","Dependence on an external service letter (ACAC Service Letter No.427 Rev B) and cross-reference to FAA AD 2005-24-10 for technical guidance"],"plain_english_summary":"This directive requires owners/operators of specified American Champion aeroplane models with flight‑control cables purchased from American Champion Aircraft Corp. before 12 August 2005 (and with <250 hours since installation) to inspect Nicopress swages on elevator, rudder, aileron and flap cables for a maximum swage width of 0.354 inches, prohibit acrobatic flight until inspection/replacement, replace any defective cables, and report defects to CASA. It transfers inspection, replacement and reporting costs to operators to prevent cable slippage and possible loss of control."},"kimi_summary":{"content_quality":"ok","complexity_score":4,"scope_assessment":{"changed":false,"description":"This is a targeted safety directive addressing a specific manufacturing defect in flight control cables. The scope remains precisely focused on the identified airworthiness risk without expansion into unrelated operational areas."},"complexity_factors":["Dual applicability criteria with overlapping model lists and date/hour thresholds","Three-tiered compliance structure with interdependent requirements (Requirement 1 conditional on Requirements 2 and 3)","Specific technical measurement requirement (0.354 inches maximum width) referencing an external service document (ACAC Service Letter No. 427 Revision B)","Precise location inventory (28 specific cable locations across 4 control systems)","Reporting obligation triggered only upon finding defects, with specific timeframe and method","Cross-reference to FAA AD 2005-24-10 indicating harmonised international regulatory action"],"plain_english_summary":"This AD requires owners of certain American Champion light aircraft (those built or fitted with control cables before 12 Aug 2005, with less than 250 flight hours) to address potentially faulty Nicopress crimped flight‑control cable ends that can slip and cause loss of control.\n\nIt imposes an immediate restriction on aerobatic flight, mandates prompt inspection of the crimp sleeves and replacement of any defective cables, and requires reporting defects to CASA to prevent in‑flight control failures."}},"importantCases":[],"_links":{"self":"/api/acts/ad-cha-29-flight-control-cables","history":"/api/acts/ad-cha-29-flight-control-cables/history","analysis":"/api/acts/ad-cha-29-flight-control-cables/analysis","conflicts":"/api/acts/ad-cha-29-flight-control-cables/conflicts","importantCases":"/api/acts/ad-cha-29-flight-control-cables/important-cases","documents":"/api/acts/ad-cha-29-flight-control-cables/documents"}}