Narrative:

Flight was the second flight on new engine after earlier 1/2 hour test flight. Pilot checked fuel prior to flight and determined left tank contained approximately 35 gallons and right tank 15 gallons. Pilot selected left tank for take off and proceeded 5-15 miles southwest from the airport to 3800 feet to monitor and document engine instruments and parameters on the planned 1.5 hour flight. Descent was initiated after 1.25 hours to return to departure airport and engine lost power at 3;000 feet. Pilot's emergency check list included consideration of fuel exhaustion but pilot dismissed this and did not switch tanks. Pilot was unable to restart engine and declared an emergency with ATC and then with the tower; but soon determined the airport was not possible and landed on a nearby freeway. The right rear main tire contacted and broke rear window of a car; but otherwise plane landed safely with no other damage or injuries. Upon inspection; the left tank had no remaining usable fuel. Pilot likely could have restarted the engine by switching to right tank; but did not do so. Pilot's historical flying profile included mostly 1 to 4 hour flights at 65% power and 13.5 to 14 gallon per hour fuel consumption. Flight profile of failed flight was atypical at 80% power with 25 gallons per hour fuel consumption for engine break in. The primary cause of the incident was the pilot's focus on engine instrumentation without properly considering and acting on fuel consumption implications. A contributing factor was that this was the pilot's first flight in plane in over three months due to engine overhaul and maintenance.

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Original NASA ASRS Text

Title: A T-210 pilot flying an engine break-in flight failed to consider the higher fuel burn associated with high power low altitude flight and exhausted the fuel in the selected tank. An emergency landing on a nearby freeway resulted.

Narrative: Flight was the second flight on new engine after earlier 1/2 hour test flight. Pilot checked fuel prior to flight and determined left tank contained approximately 35 gallons and right tank 15 gallons. Pilot selected left tank for take off and proceeded 5-15 miles SW from the airport to 3800 feet to monitor and document engine instruments and parameters on the planned 1.5 hour flight. Descent was initiated after 1.25 hours to return to departure airport and engine lost power at 3;000 feet. Pilot's emergency check list included consideration of fuel exhaustion but pilot dismissed this and did not switch tanks. Pilot was unable to restart engine and declared an emergency with ATC and then with the tower; but soon determined the airport was not possible and landed on a nearby freeway. The right rear main tire contacted and broke rear window of a car; but otherwise plane landed safely with no other damage or injuries. Upon inspection; the left tank had no remaining usable fuel. Pilot likely could have restarted the engine by switching to right tank; but did not do so. Pilot's historical flying profile included mostly 1 to 4 hour flights at 65% power and 13.5 to 14 gallon per hour fuel consumption. Flight profile of failed flight was atypical at 80% power with 25 gallons per hour fuel consumption for engine break in. The primary cause of the incident was the pilot's focus on engine instrumentation without properly considering and acting on fuel consumption implications. A contributing factor was that this was the pilot's first flight in plane in over three months due to engine overhaul and maintenance.

Data retrieved from NASA's ASRS site as of April 2012 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.