I had a cotter pinned bolt on a certified shackle today back out, start to back out anyway. The nut had fallen off, gone! It has been in service for a couple years, and is used as part of my J hook operation for setting some trusses, some of the time, for some crews. I know cotter pins, and the proper way to install them, I trust my life to them on my airplane all the time, the big difference here was the rough usage. Still it really surprised me to see that somehow, even after being thrown down, walked on, and drug (not by me but by others) that the pin managed to come free. This was the bolt that came with the shackle, nothing home brewed.
I happened to be at a buddies hangar later the same day, a full time aviation mechanic, and he also was kinda shocked that it happened. A great wake up call, obviously I was lax in my rigging inspection and should have caught it earlier, like when (assumingly) the pin was just starting to show signs of abuse. I fessed up to the crew I was working with, and suggested that it would be in their best interests to also keep an eye out for any rigging anomalies, my ultimate responsibility of course but then again, this thing was right in their faces and they didn't notice. I did, from 60' away. Out of three of these j hooks, the other two cotter pin shackle bolts look like the day I installed them, not mangled at all, making this incident even more surprising. If I ever lost a cotter pin in my airplanes control system, and the nut backed off and the bolt came out, I wouldn't be here to write about it. I have never known a castellated/cotter pinned bolt to lose a pin, but again, it must have been a freak abuse, 1 in 1000 issue, still hard to believe though.