| Date | Aircraft | Route of Flight | Time (hrs) | Total (hrs) | 
                | 01 Sep 2004 | N21481 | MKG (Muskegon, MI) - 0D1 (South Haven, MI) | 0.6 | 239.0 | 
Achilles Heel
The       thrum of the Super Decathlon's engine occasionally intensified,       reverberating through my skull with increased vigor whenever my headset       made contact with the airplane's headliner.  Off my left shoulder,       the high wing with its psuedo-Normandy stripes projected into a cobalt       void; cerulean above and turquoise below where the waters of Lake Michigan       met the cloudless sky at the horizon.  Below the starboard wing       rolled a green expanse of shoreline, demarcated from the lake by a       brilliant line of sandy beach that glowed under the evening sun.
|  | 
| Big Red and the pier at Holland, MI | 
I was an aeronautical       hitchhiker, riding in the back of Dave's Decathlon       on a thirty minute       flight along the lakeshore from our home base in South Haven to       Muskegon.  My Piper Warrior,  purchased earlier that       year, was ready       to come home from Muskegon after a radio repair.
My       airplane's avionics suite was a modest affair, primarily comprising a pair       of Bendix/King KX-170B nav/com radios.  Though old - one of them was       built before my wife was born - the words "reliable" and       "bulletproof" are often used to describe these venerable       units.  But they have an Achilles Heel, a delicate wafer switch       integral to the tuner.  One of mine had cracked, leading to       signal degradation on several frequencies.  The good folks at       Hillview Avionics in Muskegon did the repair.  Though much cheaper       than investing in new radios, this was nevertheless a costly       venture.  I suspect that labor was a significant factor: the KX-170B       is the size of a shoebox and packed to capacity with solid state circuitry.
Muskegon       Approach handed Dave off to the tower and we were instructed to enter a       left downwind for runway 24. As we rolled onto the pavement, I spotted my       Warrior in its Matterhorn White and Fighter Blue color scheme parked close       to Hillview's hangar.
|  | 
| Decathlon 68W on downwind for runway 24 at MKG | 
 Formed       Up
With the Warrior's       engine humming on the ramp, I listened to Muskegon's tower, approach, and       ATIS frequencies.  All were clear as a bell and I concluded that the       repair had been a success.  A few minutes later, I was climbing away       from Muskegon and turning south along the shoreline.  Cruising at       3000' along Lake Michigan, I heard Dave check in with the departure       controller who warned him that I was a few miles ahead.  There was       surprisingly little air traffic that night and departure did not advise me       of any airborne targets before terminating radar services at the usual       spot near       Holland.  I remained on departure frequency long enough to hear the       controller drop Dave from the system, then I toggled to an       air-to-air channel and waited.
"Warrior       481, are you on frequency?" came Dave's query.  I responded that       I was.
"Mind       if I form up?"  This was a common question whenever we flew       together.  Dave had training and experience in formation flight.        I trusted him and       was comfortable allowing the Decathlon into the little bubble of personal       space surrounding my airplane.  Not having any formal formation training       myself, I always flew in the lead position where it was my job to       navigate, watch for traffic, and not make any abrupt, unexpected maneuvers.        It was Dave's job to park himself off my wing and focus most of his       attention on the spacing between our aircraft.  I took my portion of       this partnership very seriously.  One of our fellow pilots once deliberately passed too close to a tiny cloud with Dave on his wing,       giving Dave a nasty surprise when he found himself in a cloud for a couple       of seconds.  Indeed, I tried very hard not to surprise the guy flying       close to my airplane.       
|  | 
| Dave in the Decathlon in formation with Warrior 481 on April 14, 2004 | 
"Absolutely," I responded and       throttled back to allow the Decathlon to catch up.  Despite its more       powerful engine, the Decathlon's airframe possessed more form drag than the       Warrior such that we were well matched in cruise speed.
"Can       you give me a gentle turn to the right?"  I clicked the       microphone twice in acknowledgement and banked gradually toward the       lake.  This would help him to complete the join up.  In my       peripheral vision, I saw the Decathlon appear at my four-o-clock.        Though we had done this many times, I remained fascinated by the join       up.  With both of our airplanes turning in tandem, the Decathlon moved into position       off my starboard rear       quarter.  The maneuver was so smooth, the relative motion so minor,       it seemed as though the other airplane slid along a rail projecting       rearward from my fuselage at a 45 degree angle.  With Dave tucked in       close, the Lake Michigan shoreline reappeared under my nose and I leveled       the wings to continue south.  The Decathlon moved in synchronicity as       Dave executed a series of minor power and attitude adjustments to create       the illusion that his aircraft was fixed to mine through a rigid, if       intangible, beam.
Radio       Silence       
        
Formed up, we       continued south along the shoreline for a couple of minutes before Dave       called again, "want to do some shallow turns?"
"Ok.        Let me know when you're ready," I answered.
Radio silence persisted longer than I expected.  "Do you want to       do some turns?" Dave repeated.  I echoed my previous       response.  Another minute passed before I heard from Dave again.
"I       am not receiving you.  I can hear traffic on Unicom, so I know that       my receiver is working.  Can you hear me?"
Without       thinking about it,       I responded affirmatively on the radio as my glance swept the instrument       panel.  Nothing appeared awry and I could still hear my voice       amplified over the Warrior's intercom system.  Realizing that I       probably had a transmitter problem and that Dave did not hear me, I looked over my shoulder and gave an exaggerated       nod toward the Decathlon       hovering a few yards away .  Formation       flying experts often rely on hand signals to communicate with their       wingmen, but I was not a formation flying expert and the only hand signals I knew would       not have been productive in this scenario (if ever).
"Ok,       I'm going to back off and give you more space, but we should head straight       back to South Haven now."
        
I agreed, though verbalization at this       point was obviously fruitless.  My mind immediately fixated on the       work just completed by Hillview Avionics and I became certain that the       repair must have caused some new problem.
Then        the audio panel went crazy with marker beacon lights flashing       randomly.  The cabin's overhead speaker kvetched loudly, emitting a  series of loud crackling sounds punctuated with headache       inducing squeals.  With the overhead speaker switched off at the       audio panel, it should not have been making any       noise at all.
Now I was angry.  What did those guys do to my       airplane?
Fortunately,  I did not need a radio to land at South Haven.  This       problem was a nuisance, not a catastrophe.  Just a few miles       north of South Haven, I tuned to 122.80 and listened.  Student       traffic at Allegan dominated the frequency, but I heard no transmissions       from South Haven.  If there were any airplanes in the pattern there,       they were just as radio silent as I was.
With       the overhead speaker still voicing shrill complaints,  I entered the       pattern at South Haven.  On final approach, my radio suddenly died       entirely, right in the middle of a pilot broadcasting a bandwidth-wasting       entreaty for any traffic in the pattern at Allegan to "please       advise".
"Oh, that's       f@#%ing terrific," I said aloud to no one.  But this time, I did       not hear my words amplified back at me in the headset, which meant that       the intercom was now offline.  I landed and cleared the runway,       seething over what I was convinced to be a botched avionics repair.  Outside my hangar, I switched off the transponder and avionics master       switch.  Moving to kill the       strobe lights and beacon, I saw something that made me pause.
Alternate       Causality
Any       experienced pilot reading this account has no doubt already guessed what       really happened.  It had nothing to do with the work done by Hillview       Avionics.  In fact, as far as I can tell, their work was beyond       reproach.
As I was shutting the airplane down, I glanced at the       ammeter situated on the lower right side of the Warrior's instrument panel       (left of the circuit breakers as shown in the photo below).  It was pegged at zero, indicating that the alternator was not       providing current to support the electrical demand.  I did not have       an avionics problem, the entire electrical system was dead.
Once       the Warrior's cowling was removed, the cause of the failure was       obvious.  Piper was using 1970s era Chrysler       alternators in their production aircraft when N21481 rolled off the Vero       Beach assembly line.  An integral part of my Chrysler alternator's cast       aluminum housing that attached to the front of the engine had cracked off, obviously a victim of metal fatigue.  While       the airplane logbooks describe the alternator being overhauled in the       past, the housing was probably original.  After 25 years of abuse on       the front of a vibrating airplane engine, it had obviously lost the will       to live and literally shook itself to pieces.  The guts of the poor       device were a mess.
With       this understanding, the evening's events all fell into place.  I had       probably launched into the Muskegon sky with a functional alternator - I       believe this       because I had checked the ammeter during engine run up.  At some       point, however, the alternator gave up and the battery was on its own to       support the power demands of radios, transponder, strobe lights, and other       electrical devices.  Fortunately, all systems continued working while       I was within Muskegon's airspace; I had two way radio contact with       Muskegon departure and they were reading my transponder.
Without       support from the alternator, the battery quickly discharged.        Requiring more power than any other device on board, the radio transmitter       failed first as it greedily siphoned current from the failing       battery.  From there, other systems shut down as battery power       dwindled.  Had Dave and I not flown back to South Haven together in       radio contact, I       would have never known that my transmitter failed.
        
Upon discovery of the radio problem, I became so focused       on its apparent correlation with the recent radio work that my brain       disengaged from any further troubleshooting of the problem.  Had I       simply looked at it, the ammeter would have told me all I needed to know. Although there is also an "ALT" annunciator  (idiot light) on the panel, its dim orange glow would have been washed-out by the ochre sunset spilling across the instruments at the time.
|  | 
| My panel as it looked on that day. | 
As often occurred during that first       year of aircraft ownership, this incident imparted some valuable       lessons.  I am far more careful about including the ammeter in my       scan of the panel.  I suspect it knows that I have my eye on it; it has not demonstrated any           aberrant behavior ever since.  My preflight tugs on the       alternator belt are more aggressive and I always check the security of the ammeter itself by giving the housing a good shake.
Perhaps most importantly, I learned           a lesson about fixating too quickly on a perceived root cause while           ignoring the rest of the clues provided by the airplane.  Had I           diagnosed an alternator failure while still aloft, I could have shut           down non-essential electrical systems (e.g., intercom, strobes,           transponder) and saved my radio for the landing at South Haven.
I  remember learning in ground school       how aircraft ignition systems received that altitude-critical  spark from magnetos rather than the potentially fickle electrical       system.  At the time, it seemed a very clever idea.  Now I am       sure of it.  Magnetos might represent old technology, but I am a  huge       fan of them.