Date: 201601
Local time of day: 1201-1800
Location: ZZZ.Airport, US
Flight conditions: VMC
Light: Daylight
Aircraft: Skyhawk 172/Cutlass 172
Operator: FBO
Operating under: Part 91
Flight plan: None
Mission: Ferry / Re-Positioning
Flight phase: Initial Climb
Airspace: Class D ZZZ
ATC / advisory: Tower ZZZ
Aircraft component: Engine Electric Starter
Component problem: Malfunctioning
Reporter organization: FBO
Reporter function: Pilot Flying
Reporter qualification: Flight Crew Air Transport Pilot (ATP); Flight Crew Flight Instructor; Flight Crew Instrument; Flight Crew Multiengine
Human factors: Situational Awareness
Anomaly: Aircraft Equipment Problem Less Severe; Flight Deck / Cabin / Aircraft Event Smoke / Fire / Fumes / Odor
Detector: Person Flight Crew
When detected: In-flight
Result: Air Traffic Control Issued New Clearance; Flight Crew Landed in Emergency Condition; Flight Crew Returned To Departure Airport; General Maintenance Action
Contributing factors: Aircraft; Environment - Non Weather Related; Human Factors; Procedure
Primary problem: Ambiguous

Narrative: Arrived early in the morning to preflight the aircraft; check fuel and oil. This was the last leg of my trip departing earlier in the week.  When trying to start the aircraft the starter shaft would not engage the fly wheel; but the starter motor was turning. Being the last leg to home station I decided to try and hand prop the aircraft to reach a destination where the starter could be looked at. My passenger held the brakes. A few unsuccessful attempts I talked with the mechanic at [local facility] for assistance. He informed me that they did not have a starter. He offered to heat the engine for a while with their heater. After about 30 minutes they pulled the aircraft out to the ramp where we started the aircraft and were on our way. I taxied the aircraft to runway. I completed a run up and checked all systems with no indication of anything out of tolerances. We were cleared for takeoff; about half way through the takeoff role a slight smell I could not describe was lingering. I rotated and began to climb straight out. At this point I looked back and saw smoke pouring out of the baggage area thinking to myself 'is my bag on fire?!' I opened all cabin vents; windows; and immediately [notified the] tower. Having sufficient altitude; a long runway; and an engine that was working I reduced power and made a 180 to land [opposite direction] on the runway. After landing; opening the cabin doors; and pulling off on taxi way the fire truck met me at the aircraft. The smoke had dissipated and was not present at this time. There was no indication of fire or flames. I told the fire fighter since there was no evidence of fire or smoke at this point I would taxi it back to the maintenance shop. The maintenance shop could not find the source of the problem after looking at the aircraft all day. There was a strong odor that remained in the cabin that no one could really explain. Some said it smelled like food; some said it smelled like a fried circuit board. Some had no idea how to explain the smell. I personally believe the starter must have stuck in the on position burning up the starter motor forcing the smoke into the cabin from the open heat vent. Others believe there might have been a birds nest or other object that burned up inside the engine since the aircraft had sat prior to being picked up for the ferry back a few days earlier. Seeing that most pilots do not remove engine cowlings for preflight inspections; next time I pick up a plane that has been sitting for any amount of time I will request the local shop to remove the engine cowling to inspect prior to departure and check for anything out of the ordinary.

Callback: The reporter indicated that after warming the engine compartment; the engine was started by hand propping. After returning to the field; and the starter was removed and opened for inspection. There was no evidence of damage or overheating observed. A new starter was installed and no further problems have been reported.



Synopsis: C172 pilot reported smoke and fumes from the cabin vent during takeoff that resulted in a return to the field for evaluation.