Van’s Latest LCP Update email arrived this morning. I guess they were working over the weekend, that’s good to see. The bad news is that another update will be coming “within 30 days”, or maybe that’s good news too.
Anyway, the full email is included below.
Van’s Laser-Cut Parts Replacement Program
You are receiving this email because one or more of your kits may contain laser-cut parts. This email explains the program Van’s has put in place. Additional communications to you will be forthcoming.
Background
Over the past several months Van’s Aircraft has spent thousands of hours performing testing and analysis of laser-cut parts. This includes detailed visual, rational, and computer-aided analysis, accelerated life testing, sub-assembly residual strength testing, etc. We have concluded that although many laser-cut parts have manufacturing imperfections or cracks, the strength, safety, performance, and life of the part is not adversely affected. In fact, our testing verifies that laser-cut parts are functionally equivalent to – and have a life span equivalent to – punched parts.
We have issued a revised laser-cut parts list (Revision 7), identifying several re-classifications of laser-cut parts. We also revised our recommendations concerning which parts should be replaced out of an abundance of caution, and which parts do not need to be replaced. We know customers have questions concerning our testing, analysis, conclusions, and recommendations. Later this month we will publish a detailed video presentation that will help answer these types of questions.
All tests indicate a long service life for parts with laser-cut holes. However, in the absence of significant fleet experience, Van’s Aircraft has decided out of an abundance of caution to recommend replacement of certain critical components and parts that are exposed to higher loads.
Which Laser-Cut Parts Are In My Kit?
We have prepared a customer-specific list of laser-cut parts that may have been shipped with your individual kit(s), which we will be sending to you in the near future. This list was determined by comparing the date on which each laser-cut part was first received into inventory at Van’s with the date on which each customer’s kit was packed. To be extra cautious, we defined “first date in inventory” in the published laser-cut parts list as the date on which a purchase order was first issued for a given part. The list provided for your kit represents the “worst-case scenario,” as it assumes customers received every laser-cut part that could have been available on the date the kit was packed. Because punched and laser-cut parts were comingled in inventory, upon inspection many customers may find their kit contains punched versions of some of the listed parts.
Which Parts Do I Replace and What Will It Cost?
We have recommended certain parts for replacement (red and yellow parts), which will be provided to affected customers at no charge. With some assemblies, we have identified a selection of components surrounding a red or yellow laser-cut part that may be impossible or overly burdensome to remove and replace without damage to surrounding structure. For example, RV-10/-14 aileron skins, skin stiffeners, and the trailing edge wedge are highly likely to be damaged in disassembly and reassembly. Customers who have already assembled these components will be provided skins, skin stiffeners, trailing edge wedge, and rivets at no charge. If you have completed assembly of red and yellow parts where we identified surrounding structure is highly likely to be damaged, you will need to provide us a photo showing the assembly when you order your replacement parts, so we can provide the applicable surrounding parts at no charge.
A number of laser-cut components in your kit are acceptable for use (blue and green parts), and we will not be replacing these parts. Should you choose to replace these parts, you may purchase them and request they be shipped with your red and yellow parts. If you order your blue and green parts when you request your red and yellow parts, we will discount your blue and green parts 25% off our current parts pricing. For the parts that are being provided at no charge, Van’s Aircraft will cover the shipping costs.
Kits and Aircraft Already Assembled with Laser-cut Parts
Kits and aircraft that have already been assembled with laser-cut components, including parts classified as recommended for replacement (red and yellow), are airworthy. We are currently developing service information covering the inspection and ongoing use of specific components. The method and time of compliance for inspection, repair or replacement of laser-cut parts varies based on the location of the part; however, none will require replacement in fewer than 1000 flight hours.
For certain difficult-to-replace components, we are developing engineering solutions as an optional method of compliance. Such solutions typically include adding hardware or components, or changes in hardware. When an engineering solution is used in lieu of part replacement, the completed fix will exhibit as good or better fatigue and performance as the equivalent punched component.
Customers with Quick Build Kits that Contain Laser-cut Parts
For several months, our Quick Build assembly facilities had a mixture of laser-cut and punched parts in inventory. As a result, without a complete inspection of each individual Quick Build kit, we do not know exactly which laser-cut parts were actually incorporated into that particular kit. Therefore, we will be providing customers a list of laser-cut parts which could have been incorporated into their Quick Build kit.
In addition to the assembled components in the Quick Build kit, when Van’s crates and ships these kits we include a number of additional parts which the builder assembles. Some of these parts may have been laser-cut. Therefore, each affected Quick Build customer will receive a separate list identifying all additional laser-cut parts that could have been included in their Quick Build kit on the date it was crated and shipped. All parts which Van’s is recommending for replacement out of an abundance of caution (red and yellow parts) will be provided to affected Quick Build customers at no charge.
Many Quick Build customers received pre-assembled flaps and ailerons, which may contain red and yellow laser-cut parts. Van’s will be providing all potentially affected customers the components necessary to build new flaps and ailerons from parts. We are currently evaluating an option to supply assembled flaps and ailerons for a fee. However, due to the substantial production demands we are facing there will likely be a long lead time associated with offering fully-assembled flaps and ailerons.
When Will I Be Contacted About the Replacement Parts Program?
Within 30 days, Van’s will begin emailing customers who received kits that may contain laser-cut parts, supplying a specific list of laser-cut parts that could have been included in their respective kits. During this communication process, we will ask you to let us know which parts you need. Additionally, you will have an opportunity to order other parts and hardware related to your kit assembly that you may choose to purchase and replace. We will also inform you about the availability of these parts – whether they are currently in stock or in the process of being manufactured or planned for production.
We thank you for your patience and understanding as we work through our parts replacement program and begin to deliver the parts you need. We are committed to getting replacement parts into the hands of our customers as soon as possible.
We will reach out again soon. Thank you.