Hey Dan, I’ve always heard of this from fellow mechanics but never actually seen one cracked myself. I currently have a 172 horizontal stab removed (sheared rivets at the elevator stop bracket) and thought it’d be an excellent opportunity to inspect for spar cracks while it’s on the bench. Do you happen to have any pics of a 172 with this type cracking. Thanks!
They crack outward from the center lightening hole in the forward spar, normally at 45° to the vertcal and horizontal. Cessna says that stopdrilling is OK, but I have seen those cracks continue cracking either because the stopdrill didn't clean up the end of the crack, or pilots kept pushing down on the tail.
That view is looking forward through the large hole in the stab's top skin between the two long stab/fuselage fairings.
Too many folks don't understand the geometry here. That stabilizer is a unit with the elevator as far as the air is concerned, and the center of pressure is therefore just ahead of the stab's aft spar, which is a much heavier, laminated affair to take the loads. The forward spar is very light because the air loads on it are lower. Now, that control surface is intended to govern aircraft attitudes in flight, NOT on the ground, as in flight the tail forces deal only with the force couple between the CG and CP, which are relatively close together. On the ground, a person pushing down on the stab is raising the nose against the force couple between the main gear and CG, a much larger distance, and the downforce required, on the wrong part of the stab, causes that spar to flex around that hole and it fatigues and cracks. Cessna says that if a crack progresses into the flange of the spar, it MUST be repaired with a doubler kit and maybe a new spar section if the cracks have extended far enough.
We had three 172s in the flight school. I found all of them cracked. After repairs, I forbade any of our people to push down on the stab, and we had no more trouble. That's what towbars are for. Pushing down on the stab also often buckles the nose and main ribs in the spar. It's a poor way to handle an airplane.
The SB:
https://ddrr17eur1111.cloudfront.net/wp-content/uploads/2020/04/21183259/document.pdf