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Hi Jean

Thanks for that. I thought we might have to get a new door.

Freight is going to be even more expensive from Australia...

Going to Berlin next month for work, maybe I can drop it in for repair on the way

Cheers

Robin

An update

My LAME - maintenance engineer has been talking to Diamond. The impression we get is that this is an emerging issue with the Diamond 40 and 42s.

Apparently the hinges are composed of layers of laminate, and the cracks may represent delamination rather than structural cracks. We believe that Diamond has a repair schedule for these cracks, so my LAME will be able to fix this rather than send the door to Austria.

Have a great Easter, safe flying

Robin

Robin,
My Da-40 has had similar cracks. As I recall your mechanic can pull a diagnostic procedure down from the Diamond website that will assist in determining whether or not the crack is superficial (paint only) or structural. In my case the crack was structural but my mechanic was able to effect a repair using a diamond provided replacement hinge and replacement procedure. Interestingly shortly after completing the repair in accordance with Diamond procedures the crack reappeared but has been determined to be superficial involving the paint layers only. Make sure your mechanic knows composite repair procedures thoroughly before taking this on. I treat the rear door gingerly, make sure it is closed before startup, ,etc...

Robin,
I looked in my logbooks case and found the following regarding testing procedures to determine if the cracks in your door hinge are structural or superficial. The test procedures my mechanic used are in temporary revision amm-tr-mam-42-334 titled "Improved Maintenance Instructions for the Passenger Door". Document # is 7.02.01 publication date 04 April 2009. There appears to be a torsional hinge test, a passenger door outer face hinge test and explanation of how to assess if the cracks are limited to painting only. Let me know if you need a scan and email of the instructions.

My logbook references Diamond Aircraft Repair Procedure 40.856 dated March 17, 2009 with regard to the repair that was required when it was determined that the cracking in my door unit was structural. Hope that helps you and your mechanic determine what to do next.

Hi John

Thanks very much for that. It seems that this is an emerging problem. I believe it has taken some time for my mechanic to work out where to go to next.

Being in Australia, there is a delay, so emails get sent overnight, then often need some clarification, so 3 days later we move forward.

It is now Easter and everything here in Australia closes down for a mini holiday.

Have a great Easter...

Thanks

Robin

Hi Robin,

this bracket is a weak piont. When opening the door, it should be held by hand till it is fully open. Specialy in windy conditions. After the flight, I allways open it myself and tell the Passengers in the back to wait till I open it from outside.

Thomas

Thomas wrote:Hi Robin,

this bracket is a weak piont. When opening the door, it should be held by hand till it is fully open. Specialy in windy conditions. After the flight, I allways open it myself and tell the Passengers in the back to wait till I open it from outside.

Thomas

Same here. Plus my rear hatch gets left open only in the hangar. Ten years and no cracks yet, not even in the paint...

Steve

Thanks for the feedback Steve and Thomas.

I thought I was being carefully, but obviously not careful enough.

However it worries me that in "normal" use the rear door hinges can be easily damaged.

Do we have a contact at Diamond to give them this feedback?

Regards

Robin

Robin wrote: However it worries me that in "normal" use the rear door hinges can be easily damaged.

Do we have a contact at Diamond to give them this feedback?

Regards

Robin

Contact Ken and Jeff at Diamond Canada Customer Support and express your issues and concerns. They profess to be keeping a tally of all repetitive issues with DA40's.

Ken: kschaelchlin@diamondair.com
Jeff: JKent-Rodgman@diamondair.com

This AD states:
=========================================
Actions
(1) For all S/N: Incorporate Diamond Aircraft Temporary Revision TR- MÄM 40-428, page 3-37b, dated April 30, 2010, into the FAA- approved airplane flight manual.
Compliance
Within 6 months after January 11, 2011 (the effective date of this AD).
Procedures
Follow Diamond Aircraft Temporary Revision TR-MÄM 40-428, Cover Page, dated April 30, 2010.
6
(2) For Model DA 40, S/N 40.006 through 40.009, 40.011 through 40.081, 40.084, and 40.201 through 40.749; and Model DA 40F S/N 40.FC001 through 40.FC009: Replace the rear passenger door retaining bracket with an improved design retaining bracket.
Within 6 months after January 11, 2011 (the effective date of this AD).
Follow Diamond Aircraft Industries GmbH Mandatory Service Bulletin NO. MSB 40-070 / NO. MSB D4-079 / NO. MSB F4-024, dated April 30, 2010; and Diamond Aircraft Industries GmbH Work Instruction WI-MSB 40- 070 / WI-MSB D4-079 / WI-MSB F4- 024, dated April 30, 2010.
=======================================
Any issues or comments about this now the six months period is up?