FAA Tells Bell Helicopter Owners: Swap That Cracked Cap Now
Published Date: 4/8/2026
Proposed Rule
Summary
The FAA is updating safety rules for certain Bell Textron Canada Model 505 helicopters to keep them flying safely. They want owners to keep inspecting the vertical stabilizer top end cap for cracks but now also require swapping it out with a new, stronger design that stops the need for constant checks. Helicopter owners should act before May 26, 2026, to avoid safety risks and possible extra costs.
Analyzed Economic Effects
3 provisions identified: 1 benefits, 2 costs, 0 mixed.
Replace stabilizer cap; stop recurring checks
The FAA proposes to keep the required inspections of the vertical stabilizer top end cap on certain Bell 505 helicopters and to require replacing the in-service top end cap P/N SLS-030-701-125 with the improved machined top end cap P/N SLS-704-701-101. Installing P/N SLS-704-701-101 is specified as terminating action for the repetitive detailed visual inspections described in Transport Canada AD CF-2025-32.
Estimated U.S. operator compliance costs
The FAA estimates this proposed AD would affect 150 U.S.-registered Bell 505 helicopters. Estimated costs per helicopter are: initial inspection $170 (2 work-hours at $85/hr), recurring inspections $85 (1 work-hour at $85/hr), and replacement $2,510 (6 work-hours = $510 plus $2,000 parts); estimated total costs to U.S. operators are $25,500 initial inspections, $12,750 recurring inspections, and $376,500 for replacements. The FAA says some costs may be covered under warranty by the manufacturer.
Some helicopters excluded if improved cap installed
The proposed AD would limit applicability to exclude certain serial-numbered Bell 505 helicopters that had the improved one-piece vertical stabilizer top end cap installed during production. If your helicopter already has the improved design installed at production, the proposed AD would not apply to that aircraft.
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Key Dates
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