Narrative:

Had three FAA inspectors have several questions on one of our aircraft and in the process found the flight control rigging to be incorrect. Although I'm not the maintenance outfit for the aircraft; I am the operator and hence; responsible for the plane's airworthiness. The rigging was deemed proper by five different mechanics; including myself; over a year ago. Why it has changed; how it changed; and who dunnit is unknown. All that matters now is getting it corrected; which will ultimately require a design change by the manufacturer. NTSB; FAA's aco; and the aircraft manufacturer are involved. As expected; when the current maintenance outfit re-installed the aileron after re-rigging; they installed it improperly; despite the note pointing this out in the aircraft's maintenance manual. They have now removed and reinstalled that part five times; properly.callback conversation with reporter revealed the following information: reporter stated the design features of the cirrus SR22 and SR20 are similar regarding the rudder-aileron interconnect bungee; the pitch trim; and the aileron trim cartridges. Lack of lubrication of trim cartridge and incorrect rigging of aileron travel stops; allows for over-centering of aileron trim and loss of roll control. The rigging of the aileron system requires removal of left aileron; pre-rig; aileron re-installation; then a post rig. The rudder-aileron interconnect bungee issues are centered around roll trim neutral or to either side and elevator forward; aft or neutral. The reporter believes these issues will require a design change to the aircraft flight control systems.

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Original NASA ASRS Text

Title: A CIRRUS SR22 WAS FOUND TO HAVE INCORRECT FLT CTL RIGGING DURING FAA VISIT TO A FLT SCHOOL OPERATOR.

Narrative: HAD THREE FAA INSPECTORS HAVE SEVERAL QUESTIONS ON ONE OF OUR ACFT AND IN THE PROCESS FOUND THE FLT CTL RIGGING TO BE INCORRECT. ALTHOUGH I'M NOT THE MAINT OUTFIT FOR THE ACFT; I AM THE OPERATOR AND HENCE; RESPONSIBLE FOR THE PLANE'S AIRWORTHINESS. THE RIGGING WAS DEEMED PROPER BY FIVE DIFFERENT MECHANICS; INCLUDING MYSELF; OVER A YEAR AGO. WHY IT HAS CHANGED; HOW IT CHANGED; AND WHO DUNNIT IS UNKNOWN. ALL THAT MATTERS NOW IS GETTING IT CORRECTED; WHICH WILL ULTIMATELY REQUIRE A DESIGN CHANGE BY THE MANUFACTURER. NTSB; FAA'S ACO; AND THE AIRCRAFT MANUFACTURER ARE INVOLVED. AS EXPECTED; WHEN THE CURRENT MAINT OUTFIT RE-INSTALLED THE AILERON AFTER RE-RIGGING; THEY INSTALLED IT IMPROPERLY; DESPITE THE NOTE POINTING THIS OUT IN THE ACFT'S MAINT MANUAL. THEY HAVE NOW REMOVED AND REINSTALLED THAT PART FIVE TIMES; PROPERLY.CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING INFO: RPTR STATED THE DESIGN FEATURES OF THE CIRRUS SR22 AND SR20 ARE SIMILAR REGARDING THE RUDDER-AILERON INTERCONNECT BUNGEE; THE PITCH TRIM; AND THE AILERON TRIM CARTRIDGES. LACK OF LUBRICATION OF TRIM CARTRIDGE AND INCORRECT RIGGING OF AILERON TRAVEL STOPS; ALLOWS FOR OVER-CENTERING OF AILERON TRIM AND LOSS OF ROLL CTL. THE RIGGING OF THE AILERON SYSTEM REQUIRES REMOVAL OF LEFT AILERON; PRE-RIG; AILERON RE-INSTALLATION; THEN A POST RIG. THE RUDDER-AILERON INTERCONNECT BUNGEE ISSUES ARE CENTERED AROUND ROLL TRIM NEUTRAL OR TO EITHER SIDE AND ELEVATOR FORWARD; AFT OR NEUTRAL. THE RPTR BELIEVES THESE ISSUES WILL REQUIRE A DESIGN CHANGE TO THE ACFT FLT CTL SYSTEMS.

Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.