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2022-13-07 AUTOGYRO CERTIFICATION LIMITED (TYPE CERTIFICATE PREVIOUSLY HELD BY ROTORSPORT UK LTD):
Amendment 39-22093; Docket No. FAA-2022-0685; Project Identifier MCAI-2022-00243-R.

(a) EFFECTIVE DATE

    This airworthiness directive (AD) is effective July 7, 2022.

(b) AFFECTED ADS

    None.

(c) APPLICABILITY

    This  AD  applies  to AutoGyro Certification Limited (type certificate
    previously  held  by RotorSport UK Ltd)  Model Calidus,  Cavalon,  and
    MTOsport 2017 gyroplanes, certificated in any category.

(d) SUBJECT

    Joint Aircraft Service Component (JASC) Code: 6210, Main Rotor Blades.

(e) UNSAFE CONDITION

    This AD was prompted  by reports  of rotor blade longitudinal cracking
    and rotor blade attachment bolt hole fretting corrosion and  cracking.
    The FAA is issuing this AD to prevent a rotor system from remaining in
    service  beyond its  fatigue life  and detect  fretting corrosion  and
    cracking.  The unsafe  condition, if  not addressed,  could result  in
    failure or loss of a rotor blade and subsequent loss of control of the
    gyroplane.

(f) COMPLIANCE

    Comply with this AD within the compliance times specified,  unless al-
    ready done.

(g) REQUIRED ACTIONS

(1) For  a  gyroplane  with a Rotor System I,  all part numbers and serial
    numbers, installed:

(i) That has accumulated 700 or more total hours time-in-service  (TIS) on
    the rotor system,  before further flight  after the effective  date of
    this AD, remove  the rotor system,  which includes the  rotor bearing,
    from service.

(ii) That has accumulated less than 700 total hours TIS  on the rotor sys-
     tem, before accumulating 700 total hours TIS after the effective date
     of this AD, remove the rotor system, which includes the rotor bearing
     from service.

(iii) Thereafter following paragraph (g)(1)(i) or (ii) of this AD,  remove
      the rotor system, which includes the rotor bearing, from service be-
      fore accumulating 700 total hours TIS.

(2) For a gyroplane with a Rotor System II,  all  part numbers  and serial
    numbers, installed:

(i) That has accumulated 2,500 or more total hours TIS  on the  rotor sys-
    tem, before further flight after the effective date of this AD, remove
    the rotor system, which includes the rotor bearing, from service.

(ii) That has accumulated less than 2,500 total hours  TIS  on  the  rotor
     system, before accumulating 2,500 total hours TIS after the effective
     date of this  AD, remove the  rotor system, which  includes the rotor
     bearing, from service.

(iii) Thereafter following paragraph (g)(2)(i) or (ii) of this AD,  remove
      the rotor system, which includes the rotor bearing, from service be-
      fore accumulating 2,500 total hours TIS.

(3) For  a  gyroplane  with a Rotor System I or II,  all part numbers  and
    serial numbers,  installed,  accomplish the actions  required by para-
    graph (g)(4) of this AD within 10 hours TIS  or  3  months  after  the
    effective date of this AD, whichever occurs first.

(4) For  each  rotor blade,  starting with the rotor blade bolt closest to
    the rotor hub, sequentially remove each bolt and lock nut,  remove the
    rotor blade, and remove the inner end cap.

(i) Using a dry cloth, wipe clean the rotor blade upper and lower surfaces
    within 100 mm of the circumference of each bolt hole.

(A) Dye  penetrant  inspect,  or  use a flashlight and 10X or higher power
    magnifying glass,  to  inspect the cleaned rotor blade upper and lower
    surfaces within 100 mm  of the circumference  of each bolt hole  for a
    crack, split, dent and fretting corrosion. If there is a crack, split,
    dent,  or fretting corrosion  at any point within 100 mm over the full
    circumference (360°) of a bolt hole, before further flight, remove the
    rotor system,  which includes the rotor bearing,  from service and in-
    stall airworthy parts.

(B) Using a flashlight and 10X  or higher power magnifying glass,  inspect
    each plane on the cleaned upper and lower surfaces  for bending within
    100 mm of the circumference of the bolt hole.  If there is any bending
    in any plane within 100 mm  over  the  full circumference (360°)  of a
    bolt hole, before further flight,  remove the rotor system,  which in-
    cludes the rotor bearing, from service and install airworthy parts.

(ii) Dye penetrant inspect,  or  use a flashlight and 10X  or higher power
     magnifying glass  to  inspect  the rotor blade upper and lower inside
     surfaces at the rotor blade extrusion end  (where  the  inner end cap
     was removed) for a crack,  paying particular attention for a longitu-
     dinal crack adjacent to the bolted area.  If there is a crack, before
     further flight, remove the rotor system, which includes the rotor
     bearing, from service and install airworthy parts.

Note 1 to paragraph (g)(4)(ii): Page 5 of RotorSport UK Ltd Service Infor-
mation Letter SIL-028, Issue 1, dated June 17, 2019, includes a photo of a
longitudinal blade root crack.

(iii) Using a flashlight and 10X or higher power magnifying glass, inspect
      each bolt hole  in  the rotor blade upper and lower surfaces for any
      burrs and fretting corrosion.  If there is a burr or fretting corro-
      sion, before further flight, remove the rotor system, which includes
      the rotor bearing, from service and install airworthy parts.

(iv) Using a dry cloth,  wipe clean and dye penetrant inspect,  or  use  a
     flashlight and 10X  or  higher power magnifying glass to inspect each
     bolt hole in the rotor blade upper and lower surfaces for a crack. If
     there is a crack,  before further flight,  remove  the  rotor system,
     which includes the rotor bearing,  from service and install airworthy
     parts.

(5) Thereafter following paragraph (g)(3) of this AD,  repeat  the actions
    required by paragraph (g)(4) of this AD at intervals not to exceed the
    compliance time  specified  in  paragraphs (g)(5)(i) through (iii)  of
    this AD, as applicable to your rotor system.

(i) For a gyroplane with a Rotor System I,  all  part  numbers  and serial
    numbers,  installed,  at  intervals  not to exceed 100 hours TIS or 12
    months, whichever occurs first.

(ii) For a gyroplane  with a Rotor System II,  all part numbers and serial
     numbers, installed,  that has accumulated more than 1,500 total hours
     TIS on the rotor system,  at intervals not to exceed 100 hours TIS or
     24 months, whichever occurs first.

(iii) For a gyroplane with a Rotor System II,  all part numbers and serial
      numbers,  installed,  that has accumulated 1,500 or less total hours
      TIS on the rotor system, at intervals not to exceed 500 hours TIS or
      24 months, whichever occurs first.

(h) ALTERNATIVE METHODS OF COMPLIANCE (AMOCS)

(1) The Manager, International Validation Branch,  FAA,  has the authority
    to approve AMOCs for this AD, if requested using the procedures  found
    in 14 CFR 39.19. In accordance with 14 CFR 39.19, send your request to
    your principal inspector or local Flight Standards District Office, as
    appropriate. If  sending information  directly to  the manager  of the
    International  Validation  Branch, send  it  to the  attention  of the
    person identified in paragraph (i)(1)  of this AD. Information may  be
    emailed to: 9-AVS-AIR-730-AMOC@faa.gov.

(2) Before using any approved AMOC,  notify your appropriate principal in-
    spector, or lacking  a principal inspector,  the manager of  the local
    flight standards district office/certificate holding district office.

(i) RELATED INFORMATION

(1) For more information about this AD,  contact Chirayu Gupta,  Aerospace
    Engineer,  Mechanical Systems & Administrative Services  Section,  New
    York ACO Branch, Compliance & Airworthiness Division FAA, 1600 Stewart
    Avenue, Suite 410, Westbury, NY 11590; telephone (516) 228-7300; email
    9-avs-nyaco-cos@faa.gov.

(2) RotorSport UK Ltd Service Information Letter SIL-028,  Issue 1,  dated
    June 17, 2019,  which  is  not  incorporated  by  reference,  contains
    additional information about the subject of this AD. For service infor
    -mation identified in  this  AD,  contact  Gerry Speich;  Poplar Farm,
    Wentnor, Bishops Castle,  South Shropshire,  United Kingdom,  SY9 5EJ;
    telephone +44-1588-505060; or at http://www.auto-gyro.co.uk/.  You may
    view this referenced service information  at  the  FAA,  Office of the
    Regional Counsel, Southwest Region, 10101 Hillwood Pkwy., Room 6N-321,
    Fort Worth, TX 76177.  For  information  on  the  availability of this
    material at the FAA, call (817) 222-5110.

(3) The subject of this AD is addressed in United Kingdom (UK) Civil Avia-
    tion Authority (CAA) Mandatory Permit Directive (MPD) 2022-002,  dated
    January 24, 2022.  You  may  view  the  UK  CAA  MPD  at  https://www.
    regulations.gov in Docket No. FAA-2022-0685.

(j) MATERIAL INCORPORATED BY REFERENCE

    None.

Issued on June 13, 2022.  Christina Underwood, Acting Director, Compliance
& Airworthiness Division, Aircraft Certification Service.

FOR FURTHER INFORMATION CONTACT: Chirayu Gupta, Aerospace Engineer, Mechan
-ical Systems & Administrative Services Section, New York ACO Branch, Com-
pliance & Airworthiness Division,  FAA,  1600 Stewart Avenue,  Suite  410,
Westbury, NY 11590; telephone (516) 228-7300; email 9-avs-nyaco-cos@faa.
gov.
PREAMBLE 

DEPARTMENT OF TRANSPORTATION

Federal Aviation Administration

14 CFR Part 39

[Docket No. FAA-2022-0685; Project Identifier MCAI-2022-00243-R;
Amendment 39-22093; AD 2022-13-07]
RIN 2120-AA64

Airworthiness Directives; AutoGyro Certification Limited (Type
Certificate Previously Held by RotorSport UK Ltd) Gyroplanes

AGENCY: Federal Aviation Administration (FAA), DOT.

ACTION: Final rule; request for comments.

-----------------------------------------------------------------------

SUMMARY: The FAA is adopting a new airworthiness directive (AD) for all
AutoGyro Certification Limited (type certificate previously held by
RotorSport UK Ltd) Model Calidus, Cavalon, and MTOsport 2017
gyroplanes. This AD was prompted by reports of rotor blade longitudinal
cracking and rotor blade attachment bolt hole fretting corrosion and
cracking. This AD requires reducing the life limits for the rotor
systems, repetitively inspecting each rotor blade, and depending on the
outcome, removing parts from service. The FAA is issuing this AD to
address the unsafe condition on these products.

DATES: This AD becomes effective July 7, 2022.
The FAA must receive comments on this AD by August 8, 2022.

ADDRESSES: You may send comments, using the procedures found in 14 CFR
11.43 and 11.45, by any of the following methods:
Federal eRulemaking Portal: Go to https://www.regulations.gov. Follow the instructions
for submitting comments.
Fax: (202) 493-2251.
Mail: U.S. Department of Transportation, Docket
Operations, M-30, West Building Ground Floor, Room W12-140, 1200 New
Jersey Avenue SE, Washington, DC 20590.
Hand Delivery: Deliver to Mail address above between 9
a.m. and 5 p.m., Monday through Friday, except Federal holidays.
For service information identified in this final rule, contact
Gerry Speich; Poplar Farm, Wentnor, Bishops Castle, South Shropshire,
United Kingdom, SY9 5EJ; telephone +44-1588-505060; or at
http://www.auto-gyro.co.uk/. You may view this service information at the FAA,
Office of the Regional Counsel, Southwest Region, 10101 Hillwood Pkwy.,
Room 6N-321, Fort Worth, TX 76177. For information on the availability of this material
at the FAA, call (817) 222-5110.

Examining the AD Docket


You may examine the AD docket at https://www.regulations.gov by
searching for and locating Docket No. FAA-2022-0685; or in person at
Docket Operations between 9 a.m. and 5 p.m., Monday through Friday,
except Federal holidays. The AD docket contains this final rule, the
United Kingdom (UK) Civil Aviation Authority (CAA) Mandatory Permit
Directive (MPD), any comments received, and other information. The
street address for Docket Operations is listed above.

FOR FURTHER INFORMATION CONTACT: Chirayu Gupta, Aerospace Engineer,
Mechanical Systems & Administrative Services Section, New York ACO
Branch, Compliance & Airworthiness Division, FAA, 1600 Stewart Avenue,
Suite 410, Westbury, NY 11590; telephone (516) 228-7300; email 9-avs-nyaco-cos@
faa.gov.

SUPPLEMENTARY INFORMATION:

Background

UK CAA, which is the aviation authority for the United Kingdom, has
issued UK CAA MPD 2022-002, dated January 24, 2022 (UK CAA MPD 2022-
002), to correct an unsafe condition for Autogyro Certification Limited
(formerly Rotorsport Uk Limited) Model MT-03, MTOsport, MTOsport 2017,
Calidus, and Cavalon gyroplanes. UK CAA advises of rotor blade
longitudinal cracking and rotor blade attachment bolt hole fretting
corrosion and cracking on gyroplanes with a Rotor System II installed.
According to the UK CAA, due to design similarity, this condition may
also affect gyroplanes with a Rotor System I installed. This condition,
if not addressed, could result in loss of a rotor blade and subsequent
loss of control of the gyroplane.
Accordingly, UK CAA MPD 2022-002 requires determining the
accumulated flight hours on the rotor system, complying with new life
limits for the rotor systems, and repetitively inspecting each rotor
blade to hub bar attachment fastenings and blade holes. Depending on
the outcome of the inspections, UK CAA MPD 2022-002 requires replacing
and returning parts, and reporting certain information to Autogyro
Certification Limited and the UK CAA.

FAA's Determination

These gyroplanes have been approved by the aviation authority of
the UK and are approved for operation in the United States. Pursuant to
the FAA's bilateral agreement with the UK, the UK CAA, its technical
representative, has notified the FAA of the unsafe condition described
in its MPD. The FAA is issuing this AD after evaluating all known
relevant information and determining that the unsafe condition
described previously is likely to exist or develop on other gyroplanes
of these same type designs.

Related Service Information

The FAA reviewed RotorSport UK Ltd Service Bulletin SB-144 Issue 1,
dated, August 19, 2021. This service information specifies new Rotor
System I and II life limits and new rotor blade to hub bar attachment
fastenings and blade hole inspection compliance times. This service
information also specifies a recurring inspection of the rotor system
hub bar assembly bolts.
The FAA also reviewed RotorSport UK Ltd Service Information Letter
SIL-028, Issue 1, dated June 17, 2019. This service information
provides construction and general information regarding the different
versions of Rotor System I and II and the rotor blades, and highlights
particular areas of importance of the rotor blades. This service
information specifies procedures for inspecting the blade to hub bar
joints, rotor blade surfaces and planes, and rotor blade attachment
bolt holes. This service information also specifies information
regarding and provides photos of trailing edge damage, leading edge
damage, and a longitudinal blade root crack that is adjacent to the
bolted area. Lastly, this service information provides information
regarding if there is substantial damage of a rotor blade or rotor
system.

AD Requirements

This AD requires reducing the life limits for Rotor Systems I and
II. This AD also requires repetitively removing, cleaning, and
inspecting certain areas of each rotor blade and each rotor blade bolt
hole, and depending on the outcome, removing parts from service and
installing airworthy parts.

Differences Between This AD and the UK CAA MPD

UK CAA MPD 2022-002 applies to Model MT-03 and MTOsport gyroplanes,
whereas this AD does not because those models are not FAA type-
certificated. UK CAA MPD 2022-002 requires accomplishing the initial
instance of the inspections within 100 hours or 12 months for Rotor
System I, and within 100 or 500 hours depending on accumulated usage or
2 years or 1 year (recommended) depending on operational or storage
usage for Rotor System II; whereas this AD requires accomplishing the
initial inspections within 10 hours time-in-service (TIS) or 3 months,
whichever occurs first, for a gyroplane with a Rotor System I or II,
all part numbers and serial numbers, installed. For certain Rotor
System II units, UK CAA MPD 2022-002 recommends a shorter recurring
inspection time; whereas this AD does not. This AD requires wiping the
inspection areas of the rotor blades clean before accomplishing the
inspections; whereas UK CAA MPD 2022-002 does not. UK CAA MPD 2022-002
refers to service information that states that ``means of inspection
can be dye penetrant or visual high magnification or as determined
appropriate by the inspector;'' whereas this AD mandates what types of
inspections must be accomplished. UK CAA MPD 2022-002 requires
returning parts to the manufacturer, whereas this AD does not. UK CAA
MPD 2022-002 requires reporting certain information; whereas this AD
does not.

Justification for Immediate Adoption and Determination of the Effective
Date


Section 553(b)(3)(B) of the Administrative Procedure Act (APA) (5
U.S.C. 551 et seq.) authorizes agencies to dispense with notice and
comment procedures for rules when the agency, for ``good cause,'' finds
that those procedures are ``impracticable, unnecessary, or contrary to
the public interest.'' Under this section, an agency, upon finding good
cause, may issue a final rule without providing notice and seeking
comment prior to issuance. Further, section 553(d) of the APA
authorizes agencies to make rules effective in less than thirty days,
upon a finding of good cause.
An unsafe condition exists that requires the immediate adoption of
this AD without providing an opportunity for public comments prior to
adoption. The FAA has found that the risk to the flying public
justifies foregoing notice and comment prior to adoption of this rule
because cracking and fretting on the surfaces of the rotor blades can
lead to degradation or structural failure of the rotor system and
subsequent loss of control of the gyroplane. Loss of aerodynamic
control due to the mentioned unsafe condition could ultimately be
categorized as a catastrophic failure. In addition, the FAA has no
information regarding the number of rotor blades that are in service
beyond their fatigue life or pertaining to the extent of cracking or
corrosion of rotor blades that may currently exist in gyroplanes or how
quickly the condition may propagate to
failure. In light of this, this AD reduces the life limit threshold of
the rotor systems and the initial instance of the rotor blade
inspections required by this AD must be accomplished within 10 hours
TIS or 3 months, whichever occurs first. This compliance time is
shorter than the time necessary for the public to comment and for
publication of the final rule. Accordingly, notice and opportunity for
prior public comment are impracticable and contrary to the public
interest pursuant to 5 U.S.C. 553(b)(3)(B).
In addition, the FAA finds that good cause exists pursuant to 5
U.S.C. 553(d) for making this amendment effective in less than 30 days,
for the same reasons the FAA found good cause to forego notice and
comment.

Comments Invited

The FAA invites you to send any written data, views, or arguments
about this final rule. Send your comments to an address listed under
ADDRESSES. Include ``Docket No. FAA-2022-0685; Project Identifier MCAI-
2022-00243-R'' at the beginning of your comments. The most helpful
comments reference a specific portion of the final rule, explain the
reason for any recommended change, and include supporting data. The FAA
will consider all comments received by the closing date and may amend
this final rule because of those comments.
Except for Confidential Business Information (CBI) as described in
the following paragraph, and other information as described in 14 CFR
11.35, the FAA will post all comments received, without change, to
https://www.regulations.gov, including any personal information you
provide. The agency will also post a report summarizing each
substantive verbal contact received about this final rule.

Confidential Business Information


CBI is commercial or financial information that is both customarily
and actually treated as private by its owner. Under the Freedom of
Information Act (FOIA) (5 U.S.C. 552), CBI is exempt from public
disclosure. If your comments responsive to this AD contain commercial
or financial information that is customarily treated as private, that
you actually treat as private, and that is relevant or responsive to
this AD, it is important that you clearly designate the submitted
comments as CBI. Please mark each page of your submission containing
CBI as ``PROPIN.'' The FAA will treat such marked submissions as
confidential under the FOIA, and they will not be placed in the public
docket of this AD. Submissions containing CBI should be sent to Chirayu
Gupta, Aerospace Engineer, Mechanical Systems & Administrative Services
Section, New York ACO Branch, Compliance & Airworthiness Division, FAA,
1600 Stewart Avenue, Suite 410, Westbury, NY 11590; telephone (516)
228-7300; email 9-avs-nyaco-cos@faa.gov. Any commentary that the FAA
receives which is not specifically designated as CBI will be placed in
the public docket for this rulemaking.

Regulatory Flexibility Act

The requirements of the Regulatory Flexibility Act (RFA) do not
apply when an agency finds good cause pursuant to 5 U.S.C. 553 to adopt
a rule without prior notice and comment. Because the FAA has determined
that it has good cause to adopt this rule without prior notice and
comment, RFA analysis is not required.

Costs of Compliance

The FAA estimates that this AD affects 41 gyroplanes of U.S.
Registry. Labor rates are estimated at $85 per work-hour. Based on
these numbers, the FAA estimates the following costs to comply with
this AD.
Replacing a rotor system takes about 1.5 hours and parts cost about
$5,500 for an estimated cost of $5,628 per gyroplane and $230,748 for
the U.S. fleet, per instance. Inspecting a rotor system takes about 1
work-hour for an estimated cost of $85 per gyroplane and $3,485 for the
U.S. fleet, per inspection cycle.

Authority for This Rulemaking

Title 49 of the United States Code specifies the FAA's authority to
issue rules on aviation safety. Subtitle I, section 106, describes the
authority of the FAA Administrator. Subtitle VII: Aviation Programs,
describes in more detail the scope of the Agency's authority.
The FAA is issuing this rulemaking under the authority described in
Subtitle VII, Part A, Subpart III, Section 44701: General requirements.
Under that section, Congress charges the FAA with promoting safe flight
of civil aircraft in air commerce by prescribing regulations for
practices, methods, and procedures the Administrator finds necessary
for safety in air commerce. This regulation is within the scope of that
authority because it addresses an unsafe condition that is likely to
exist or develop on products identified in this rulemaking action.

Regulatory Findings

This AD will not have federalism implications under Executive Order
13132. This AD will not have a substantial direct effect on the States,
on the relationship between the national Government and the States, or
on the distribution of power and responsibilities among the various
levels of government.
For the reasons discussed, I certify that this AD:
(1) Is not a ``significant regulatory action'' under Executive
Order 12866, and
(2) Will not affect intrastate aviation in Alaska.

List of Subjects in 14 CFR Part 39

Air transportation, Aircraft, Aviation safety, Incorporation by
reference, Safety.

The Amendment

Accordingly, under the authority delegated to me by the
Administrator, the FAA amends 14 CFR part 39 as follows:

PART 39--AIRWORTHINESS DIRECTIVES

1. The authority citation for part 39 continues to read as follows:

Authority: 49 U.S.C. 106(g), 40113, 44701.

Sec. 39.13 [Amended]

2. The FAA amends Sec. 39.13 by adding the following new airworthiness
directive: