Narrative:

On takeoff roll everything indicated normal. After rotation, we heard a loud noise and the aircraft acted as if in a V1 cut situation. After gear and flaps were put up, the aircraft acted normally and we continued takeoff and immediately returned to the airport because the engine noises indicated that the emergency door had come open. After landing and during taxi everything appeared to be normal. However, the mechanic discovered that some pieces of mail from the cargo had entered the engine. On normal preflight, all indications were that the door was locked and closed. However, during that time there was loading of the aircraft which was done in a very rushed manner. Due to the construction of the handle and the fact that it is not covered in any way, the shifting of freight during rotation may have jarred the handle open. In my opinion there should be an ad note to cargo operators using this type of aircraft advising them of this potential problem. Suggestions should be made to either protect the handle in some way and/or to warn cargo handlers to use care when loading parcels into the area near the emergency door. Callback conversation with reporter revealed the following: reporter indicates not the first time this problem has occurred. Door is located about 1/2 way back on cabin section and 6-8' in front of engine. Ingested mail damaged only turbine blades. Not extensive, just expensive. Hopes that company and FAA will work out a way so this will not happen again.

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Original NASA ASRS Text

Title: EMERGENCY DOOR OPENED AT TKOF.

Narrative: ON TKOF ROLL EVERYTHING INDICATED NORMAL. AFTER ROTATION, WE HEARD A LOUD NOISE AND THE ACFT ACTED AS IF IN A V1 CUT SITUATION. AFTER GEAR AND FLAPS WERE PUT UP, THE ACFT ACTED NORMALLY AND WE CONTINUED TKOF AND IMMEDIATELY RETURNED TO THE ARPT BECAUSE THE ENG NOISES INDICATED THAT THE EMER DOOR HAD COME OPEN. AFTER LNDG AND DURING TAXI EVERYTHING APPEARED TO BE NORMAL. HOWEVER, THE MECH DISCOVERED THAT SOME PIECES OF MAIL FROM THE CARGO HAD ENTERED THE ENG. ON NORMAL PREFLT, ALL INDICATIONS WERE THAT THE DOOR WAS LOCKED AND CLOSED. HOWEVER, DURING THAT TIME THERE WAS LOADING OF THE ACFT WHICH WAS DONE IN A VERY RUSHED MANNER. DUE TO THE CONSTRUCTION OF THE HANDLE AND THE FACT THAT IT IS NOT COVERED IN ANY WAY, THE SHIFTING OF FREIGHT DURING ROTATION MAY HAVE JARRED THE HANDLE OPEN. IN MY OPINION THERE SHOULD BE AN AD NOTE TO CARGO OPERATORS USING THIS TYPE OF ACFT ADVISING THEM OF THIS POTENTIAL PROB. SUGGESTIONS SHOULD BE MADE TO EITHER PROTECT THE HANDLE IN SOME WAY AND/OR TO WARN CARGO HANDLERS TO USE CARE WHEN LOADING PARCELS INTO THE AREA NEAR THE EMER DOOR. CALLBACK CONVERSATION WITH RPTR REVEALED THE FOLLOWING: RPTR INDICATES NOT THE FIRST TIME THIS PROBLEM HAS OCCURRED. DOOR IS LOCATED ABOUT 1/2 WAY BACK ON CABIN SECTION AND 6-8' IN FRONT OF ENG. INGESTED MAIL DAMAGED ONLY TURBINE BLADES. NOT EXTENSIVE, JUST EXPENSIVE. HOPES THAT COMPANY AND FAA WILL WORK OUT A WAY SO THIS WILL NOT HAPPEN AGAIN.

Data retrieved from NASA's ASRS site as of August 2007 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.