Warned Management Of 'Impending Disaster'

New evidence suggests Chalks' management knew poor maintenance was contributing to more and more dangerous inflight emergencies in the months leading up to last December's fatal crash of a Grumman Mallard seaplane which claimed the lives of 20 passengers and crew.

The Miami Herald reports prior to the fatal accident, three pilots working for Chalks resigned on fears poor maintenance might result in tragedy. In their resignation letters, each outlined recent incidents directly related to the aging fleet and the company's miserly approach to maintenance.

The NTSB's final report on last December's crash hasn't been released yet, but the preliminary report noted fatigue cracking on the rear spar cap of the wing that separated from the aircraft in flight.

An emergency AD issued following that crash would entail the removal of wing skins and likely prove more costly than the worth of the aircraft. The Herald says Chalks has petitioned the FAA to use an alternate inspection method.

The airline was in bankruptcy in 1999 when current owner Jim Confalone bought it. He brought it out of bankruptcy, but has since had problems keeping costs down. Controlling costs is imperative in today's competitive airline market, but many wonder if Chalks has cut things a little too close to the bone.

Chalks captain Eric Weber told the NTSB the airline employed 12 mechanics when he began flying for it in 2001. By 2004 that number had halved. Another former pilot told the NTSB in October 2004 the maintenance department had orders not buy any more parts for the rest of the year.

In another instance, a former first officer found a rag stuffed in an area where he had repeatedly reported fuel leaks in the past. His captain on that flight, Grady Washatka, refused to fly the aircraft.

In fact, the airline's pilots became so concerned with what they considered sub-par maintenance, they asked the company's director of operations Roger Nair to climb a ladder and inspect for himself missing rivets and cracks on the right wing of N2969 -- the same plane that later lost its right wing and plunged into the water last December.

Reportedly, Nair promised the pilots to address and fix all the problems.

Former pilot Washatka said Nair later threatened to discipline him if he continued to point out so many maintenance problems. In his resignation letter Washatka bashed the airline for claiming a corroded pitch-trim control cable that failed on one of its aircraft inflight parted in a difficult-to-inspect area. Washatka said removing one panel with only 17 screws would have allowed a proper inspection.

In an eerie and tragic prediction, Washatka's January 2005 resignation letter warned of "impending disaster."

Chalks' fleet of seaplanes remains grounded until an approved procedure to inspect and repair wing cracks found in the spars of all four is approved.

The company recently resumed operations between Miami and the Bahamas operating a fleet of 19-seat Beech 1900 turboprops.

FMI: www.ntsb.gov, www.flychalks.com