DG-505 crash at North Hill Airfield during solo flight approach
On April 22, 2007, a DG Flugzeugbau DG-505 Elan Orion crashed at North Hill Airfield, Honiton, Devon during a solo flight. The experienced pilot, who was undergoing conversion training on the DG-505, entered a steep dive on approach, resulting in the aircraft striking the ground. The pilot sustained serious injuries, and the aircraft was destroyed. The investigation revealed that a failure of the electric cable used to restrain the rear cockpit headrest led to a loss of control.
- Approach and landing: After an uneventful winch launch and normal circuit, the glider turned onto final approach at appropriate height and speed under supervision of the duty instructor.
- Headrest cable failure: During final approach the non‑standard electrical cable restraining the rear cockpit hinged headrest failed at its attachment to the rear shoulder harness point, allowing the headrest to move freely.
- Unapproved restraint cable: The original manufacturer‑specified nylon/perlon headrest cords had previously been replaced by an electrical cable of different material and properties, which was accepted by club members and not identified as non‑compliant during inspections.
- Inadequate inspection regime: The relevant Technical Note and Flight Manual revision requiring daily inspection of the rear headrest ropes was not incorporated into the cockpit Flight Manual copy and was not effectively acted upon during annual and daily inspections.
- Headrest jams controls: With the restraining cable failed, the rear headrest pivoted forward onto the rear control column and then dropped behind it, preventing rearward movement of the column and restricting elevator up‑deflection.
- Unrecoverable steep dive: The restriction of rearward control column travel caused the glider to adopt a steep nose‑down attitude on final approach and descend rapidly with little change in attitude until ground impact.
- Crash - serious injury: The glider struck the ground nose‑first, bounced with tail impact and tailplane separation, then impacted again and was destroyed, seriously injuring the pilot.