2026-18468Proposed RuleWallet

Bell Choppers Face Tailcone Fastener Inspection Mandate

Published Date: 9/10/2026

Proposed Rule

Summary

The FAA proposes to adopt a new airworthiness directive (AD) for certain Bell Textron Canada Limited Model 505 helicopters. This proposed AD was prompted by a quality escape affecting certain tailcone assemblies. This proposed AD would require replacing any tailcone assembly that has exceeded a certain life limit. Also, this proposed AD would require inspecting the tailcone assembly for gaps, and repetitively inspecting the tailcone assembly for loose, damaged, or missing fasteners. Depending on the results of these inspections, this proposed AD would require conducting further inspections and corrective actions. The FAA is proposing this AD to address the unsafe condition on these products.

Analyzed Economic Effects

4 provisions identified: 1 benefits, 3 costs, 0 mixed.

Mandatory Tailcone Replacement When Life Limit Exceeded

The proposed AD would require replacing any tailcone assembly that has exceeded its airworthiness life limit. The FAA estimates replacing a tailcone costs 30 work-hours (30 x $85/hr = $2,550) plus $54,280 in parts, for a total estimated cost per replacement of $56,830.

Estimated U.S. Fleet Compliance Costs

The FAA estimates this AD would affect 190 U.S.-registered Bell Model 505 helicopters. Estimated costs to U.S. operators are $64,600 for the gap inspections (190 × $340), $48,450 for the fastener inspections (190 × $255), and a potential $10,797,700 if all 190 helicopters required a tailcone replacement (190 × $56,830).

Safety Benefit: Prevent Tailboom Separation

The AD aims to detect and correct crack initiation in the tailboom skin to prevent a tailboom skin fracture and possible separation from the fuselage, which could cause loss of control of the helicopter. The requirement to inspect and replace affected tailcone assemblies is intended to address that unsafe condition.

Required Tailcone Inspections and Checks

If you operate a Bell Model 505 helicopter on the U.S. registry, you must inspect the tailcone assembly for gaps and repetitively inspect for loose, damaged, or missing fasteners. The FAA estimates the initial gap inspection takes 4 work-hours (4 x $85/hr = $340) and the fastener inspection takes 3 work-hours (3 x $85/hr = $255); repetitive on-condition inspections are estimated at 1 work-hour ($85).

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Key Dates

Published Date
Comments Due
9/10/2026
10/26/2026

Department and Agencies

Department
Independent Agency
Agency
Transportation Department
Federal Aviation Administration
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