This amendment adopts a new AD for Robinson Model R-22 series helicopters that have been modified with door assemblies manufactured by Tech-Tool Plastics, Inc., in accordance with STC No. SR09189RC. This action requires: \n\n\tWithin 30 days, inspecting each door assembly integral frame for a crack, and before further flight, replacing the left-hand door assembly, part number (P/N) R-22-101-51 or P/N R-22-101-53, or right-hand door assembly, P/N R-22-101-52 or P/N R-22-101-54, if a crack is found; \n\n\tWithin 30 days, if crack is not found on a door assembly, inspecting the door assembly weather seal set to determine if it is airworthy and installed properly, and if it is not, before further flight, reinstalling or replacing the weather seal set with weather seal set, P/N 74418x14L and P/N 74814x12BL, or with any other appropriate airworthy weather seal set; \n\n\tWithin 30 days, if a crack is not found on a door assembly, inspecting to determine that a cotterpin, P/N MS24665-136, is installed properly in each of the two hinges on the door assembly, and if it is not, before further flight, properly installing the cotter pin; \n\n\tThereafter, at intervals not to exceed 100 hours (TIS), inspecting each door assembly integral frame for a crack and replacing the door assembly if a crack is found; and, \n\n\tWithin 30 days after discovering a crack, reporting that information as well as the helicopter model to the FAA. You may submit your report via mail, Fax, or telephone to the FAA, ATTN: ASW-170 (Marc Belhumeur), 2601 Meacham Blvd., Fort Worth, Texas 76137; telephone: (817) 222-5177; Fax: (817) 222-5783. \n\n\tThis amendment is prompted by an accident on November 27, 2004, involving a Robinson Model R-22 Beta helicopter, which resulted in two fatalities. This amendment is also prompted by one incident involving a Robinson Model R-22 series helicopter, which was reported to Tech-Tool Plastics, Inc., the door assembly manufacturer, on September 20, 2004. A preliminary investigation of the helicopter involved in the accident indicated that the doors separated from the helicopter at some undetermined time and that the separation may have been partially due to the door hinge cotter pins not being installed properly. In the incident, an operator reported that the window in the pilot door had separated from the helicopter during flight at an altitude of 4,500 feet. Subsequent investigation revealed cracking across the composite door assembly integral frame stiffener bead, just beneath the lower hinge on the forward edge of the door, and at the upper and lower door cam lock on the trailing edge of the door. Further investigation revealed that the door weather seal set was not the weather seal set supplied by the door assembly manufacturer. Additionally, the two nylon adjustment screws, which are required to relieve excessive force on the door hinges, were broken or missing. Finally, the door may not have been trimmed to the cabin door opening as stated in the manufacturer's door assembly installation drawings. The actions specified in this AD are intended to prevent separation of a door window or door assembly from the helicopter, which could damage the tail rotor during flight and result in loss of control of the helicopter. \n\n\tWe have reviewed Tech-Tool Plastics, Inc. Installation Instructions, TTP-1R, Revision A, dated November 21, 1997, which is part of STC SR09189RC authorizing installation of door assemblies on these affected helicopters. We have also reviewed Tech-Tool Plastics, Inc. Service Bulletin No. TTP2005-01, Revision A, dated February 1, 2005 (SB), which describes procedures for a one-time visual inspection for cracks and proper installation of the door assemblies and before the first flight of each day recurring visual checks for cracks. The SB also includes weather seal set and cotter pin installation instructions that were inadvertently omitted from the Installation Instructions of TTP-1R, Revision A, dated November 21 1997. Cracks in a helicopter door or improper installation create an unsafe condition. \n\n\tThis unsafe condition is likely to exist or develop on other helicopters of the same supplemental type design. Therefore, this AD is being issued to prevent separation of a door window or door assembly from the helicopter, which could damage the tail rotor during flight and result in loss of control of the helicopter. This AD requires inspecting the left-hand door and right-hand door for a crack in the door assembly integral frame, and replacing the door assembly if a crack is found. This AD also requires inspecting each door assembly to determine if the weather seal set is airworthy and installed properly, inspecting each door hinge for the proper installation of a cotter pin, and inspecting each door assembly integral frame for a crack at intervals not to exceed 100 hours TIS. Also, reporting the results of the inspections to the FAA is required if a crack is found.Accomplish the required actions in accordance with the specified portions of the service information described previously. The short compliance time involved is required because the previously described critical unsafe condition can adversely affect the structural integrity and controllability of the helicopter. Since the one-time inspections of each door assembly frame, cotter pins, and weather seal set are required within 30 days, and because each 100-hour TIS interval for inspecting each door assembly frame for cracking may occur within 30 calendar days for those helicopters being used for training or other high usage missions, this AD must be issued immediately. \n\n\tSince a situation exists that requires the immediate adoption of this regulation, it is found that notice and opportunity for prior public comment hereon are impracticable, and that good cause exists for making this amendment effective in less than 30 days. \n\n\tWe estimate that this AD will affect 200 helicopters of U.S. registry, and the actions will take approximately: \n\n\t.1 work hour to inspect for cracking in each door assembly integral frame; \n\n\t.1 work hour to inspect the weather seal set, and both cotter pins in each door assembly; and \n\n\t.5 work hour to install each door assembly. \n\nThe average labor rate is $65 per work hour. Required parts will cost approximately $4,464 per helicopter if replacing each door assembly and reinstalling and trimming each door is required. Based on these figures, we estimate the total cost impact of the AD on U.S. operators to be $1,857,400, assuming 366 inspections for cracking in each door assembly integral frame are accomplished, and that both door assemblies on all Robinson Model R-22 series helicopters are replaced. \n\nComments Invited \n\n\tThis AD is a final rule that involves requirements that affect flight safety and was not preceded by notice and an opportunity for public comment; however, we invite you to submit any written data, views, or arguments regarding this AD. Send your comments to an address listed under ADDRESSES. Include "Docket No. FAA-2005-14210; Directorate Identifier 2005-SW-05-AD" at the beginning of your comments. We specifically invite comments on the overall regulatory, economic, environmental, and energy aspects of the AD. We will consider all comments received by the closing date and may amend the AD in light of those comments. \n\n\tWe will post all comments we receive, without change, to http://dms.dot.gov , including any personal information you provide. We will also post a report summarizing each substantive verbal contact with FAA personnel concerning this AD. Using the search function of our docket web site, you can find and read the comments to any of our dockets, including the name of the individual who sent the comment. You may review the DOT's complete Privacy Act Statement in the Federal Register published on April 11, 2000 (65 FR 19477-78), or you may visit http://dms.dot.gov . \n\nRegulatory Findings \n\n\tWe have determined that this AD will not have federalism implications under Executive Order 13132. This AD will not have a substantial direct effect on the States, on the relationship between the national Government and the States, or on the distribution of power and responsibilities among the various levels of government. \n\n\tFor the reasons discussed above, I certify that the regulation: \n\n\t1. Is not a "significant regulatory action" under Executive Order 12866; \n\n\t2. Is not a "significant rule" under the DOT Regulatory Policies and Procedures (44 FR 11034, February 26, 1979); and \n\n\t3. Will not have a significant economic impact, positive or negative, on a substantial number of small entities under the criteria of the Regulatory Flexibility Act. \n\n\tWe prepared an economic evaluation of the estimated costs to comply with this AD. See the DMS to examine the economic evaluation. \n\nAuthority for This Rulemaking \n\n\tTitle 49 of the United States Code specifies the FAA's authority to issue rules on aviation safety. Subtitle I, section 106, describes the authority of the FAA Administrator. Subtitle VII, Aviation Programs, describes in more detail the scope of the Agency's authority. \n\n\tWe are issuing this rulemaking under the authority described in subtitle VII, part A, subpart III, section 44701, "General requirements." Under that section, Congress charges the FAA with promoting safe flight of civil aircraft in air commerce by prescribing regulations for practices, methods, and procedures the Administrator finds necessary for safety in air commerce. This regulation is within the scope of that authority because it addresses an unsafe condition that is likely to exist or develop on products identified in this rulemaking action. \n\nList of Subjects in 14 CFR Part 39 \n\n\tAir transportation, Aircraft, Aviation safety, Incorporation by reference, Safety. \n\nAdoption of the Amendment \n\nAccordingly, pursuant to the authority delegated to meby the Administrator, the Federal Aviation Administration amends part 39 of the Federal Aviation Regulations (14 CFR part 39) as follows: \n\nPART 39--AIRWORTHINESS DIRECTIVES \n\n1. The authority citation for part 39 continues to read as follows: \n\n\tAuthority: 49 U.S.C. 106(g), 40113, 44701. \n\nSec. 39.13 (Amended) \n\n2. Section 39.13 is amended by adding a new airworthiness directive to read as follows: