Helicycle Hatchery [Archive] - Page 4

StanFoster

05-02-2009, 03:57 PM

I worked on the Helicycle all morning today. Todays mission was to install the top fuel tank....seal off the bottom outlets with a connecting hose...and fill it with gasoline to check for leaks. I am always a little aprehensive about potential leaks....but I was pleased that I could not find any seepage. I let it set in there several hours...then did a final check with my propane lighter just to make sure. :boom:

No fire or explosions...so I was given the green light to reinstall my fresh painted transmission.

I will install my newly painted burgundy tail rotor driveshaft when it gets back from my painter...along with the floor/seatpan.

It looks like I may be waiting on my third shipment...it was supposed to be here in April.

Stan

RotoPlane

05-02-2009, 04:07 PM

Expect your fire insurance rate to increase shortly......

Chopper Reid

05-02-2009, 05:21 PM

Expect your fire insurance rate to increase shortly......

My thoughts exactly!! Stan, a room with jerry cans isnt the best place to use a lighter, those cans can let off a lot of vapour in and enclosed room !!

StanFoster

05-02-2009, 05:46 PM

gyrodrifter

05-02-2009, 06:12 PM

Brad- I love that #17 ceiling fan! You and Mikayla rock. John...... the tailrotor gearbox and the transmission were prepped, primed, and rattle canned with RustOleum paint. Stan

Aaaahhhh... sooooooh,

Good ol' Boat paint :D, It'll fly!!

Looking like a million bucks Stan, I know that paint does a good job, used it many times.
I used that on the boat, rolled it on and then tipped it to a nice finish.
Came out like glass.

I would love to be able to be there when you take it to a hover the first time,
I'd shoot a million pics just to get to nail that right one. Those "first ever" pics are the ones you can never replace.

Take care, John.

Kandace

05-02-2009, 06:19 PM

...but I was pleased that I could not find any seepage. I let it set in there several hours...then did a final check with my propane lighter just to make sure. :boom:

No fire or explosions...so I was given the green light to reinstall my fresh painted transmission.

It looks like I may be waiting on my third shipment...it was supposed to be here in April.

Stan

That is funny! Propane lighter! :boink:

You sure have a good sense of humor Stan!

Kandace

gyrodrifter

05-02-2009, 06:29 PM

Arnie--Thanks again.....your comments are always welcome...maybe not deserved.....

This thread has just begun......I still have the wiring...instruments...clutch, swashplate....rotorhead, blades.....and that T-62 turbine to install.

Stan

(You are too modest Stan)

Dat is good ya...,

We all growink wit you on dis!... we look we see...For later wen we will bild ein machine too ya?

Anyway... when you get to that turbine, I'll be glued to the posts and I'll be paying tons of attention, Turbines touch strings and make music, can't wait.

You have an audience Stan :D, more power to you friend!

Regards,
John.

RotoPlane

05-02-2009, 06:52 PM

Stan, I knew you were kidding about the lighter……so was I. Guess I should use these…:).

Passin' Thru

05-02-2009, 08:10 PM

Stan, I knew you were kidding about the lighter……so was I. Guess I should use these…:).

Well, I'll admit he had me going there for a bit! Nearly gave me a heart attack!:eek:
I was totally discombobulated! I just sat there saying "WTF?" :confused:This can't be real! I must be dreaming this, I'll wake up in a minute. :der:
.

All_In

05-02-2009, 09:09 PM

Geesshh guys......that picture with a lighter was staged! You guys must think I am the stupidest person that ever pooped between two boots!

I had just moved those cans into the room...then took the picture.

I am going to leave my internet humor alone!

Stan
It's cracked me up!!!!
If I had more time I would have pasted up a photo with an explosion in it!

StanFoster

05-03-2009, 04:29 PM

I am pre studying better wiring methods before I get my next shipment which will have all the wiring and instruments.

The latest issue of Experimental Helo magazine had an article that felt like it was directed just at me.

I was from the school of crimp and solder every terminal. I know now that is not the best way...but I wasnt enlightened so much as by this latest article.
I dont have permission to scan the article ...but I went to look up MIL-T-7928. Up came the basically the same information.

I hope when my wiring package comes...it has these type of connectors...or I will just order them myself. I imagine Helicycle will send the best..as so far they have done everything top notch.

The article explains clearly about having the proper crimping tool....strain relief is very important...no solder....etc. Then I will be crimping and doing some pull testing to see that the wire wont break at the terminal...but elsewheres. These special crimping tools actually work harden the wired so it is stonger insided the terminal.

Interesting to say the least....and I am glad I read that article.

Here is a link to a good site showing some of what I mentioned above.

I want to do it like an electrician would.....without shorts!!

http://www.mechanicsupport.com/articleTerminals.html

Stan

HobbyCAD

05-03-2009, 06:13 PM

Hi There Stan,

Have been following your build, but never posted anything. Nice job you're doing.

I'm so glad you have seen the light, and now realise solder is BAD for aircraft connector wiring. There has been a couple of threads on the subjects, I've always advocated CRIMP ONLY, but still, some of the die-hard "we think we are better than others" always came back and said, solder, no worries, or be secure, do both !! Thanks for showing them the correct way. I would have thought this forum contained some AP's, or Avionics specialists, that would have proved their worth. Seemingly not ..................

Harry_S.

05-04-2009, 01:05 PM

If you want the best Quality Engineering, Stan, following the Mil Specs. is the only way to go. I worked to Mil Spec for over 30 yrs. and even preached it here on the forum. You can't beat it, plus there's not a procedure too complicated.

Ref. contact and terminal crimps. At McDonnell Aircraft, thousands upon thousands of crimps were made every work day, the majority were by automatic machines fed one wire at a time by a human operator. At the beginning of every work shift, a sample crimp of each machine and the hand crimpers to be used were tagged and submitted to Quality Assurance for a pull test.

The pneumatic test machines were pre-set to the min. pull required to pass. Any sample crimp that pulled out prior to the min. was rejected and returned to the crimper and the crimper was Red tagged. The crimpers were well maintained and consequently hardly ever had rejects, but we were still required to submit the daily samples for each crimper.

Abiding per the Mil Specs was a bit expensive? yeah, I guess so but...Quality was No. One. Even our Vendors had to work per the Mil Spec.

Pardon my rant here. No hijack intended. :peace:

Cheers :)

StanFoster

05-04-2009, 05:15 PM

Harry- Your expertise is welcome...and definately is no rant. My weakness on my other builds was my wiring. I want this Helicycle done as correctly as I can. I am going to be doing a pull test when I get the good type crimpers...and compare it to my regular hardware store crimpers I have used.
It will be interesting. I am thorughly convinced to leave that solder gun in the drawer.

Thanks again Harry...good hearing from you.

Stan

StanFoster

05-04-2009, 05:24 PM

I am getting excited now....the other fuel tanks are getting prepped...and will be in this week. I had to fish several of the o-ring attachment bolts inside the tanks..and out their holes with some safety wire.

I then nestled the lower tanks into place to measure the length of the connecting hoses.

The last pictures are the access holes being sealed up.

I will fill all the tanks and leak test the whole system later this week if all goes according to plans. I will have several chances to work on these tanks during glueups in the stairshop.

Stan

Chopper Reid

05-04-2009, 07:58 PM

Geesshh guys......that picture with a lighter was staged! You guys must think I am the stupidest person that ever pooped between two boots!

I had just moved those cans into the room...then took the picture.

I am going to leave my internet humor alone!

Stan

Nope, I certainly do not think you are at all stupid Stan but I have seen some odd things happen to even the best people.

I look forward to seeing your posts Stan every time I log into this forum as you are doing a fine job there.

StanFoster

05-05-2009, 02:58 AM

Bran- I definately am not free of doing stupid things in my life.....some of the stuff I have done I wont talk about...it was so stupid!:yo:

Glad you are enjoying this build.....posting slow but steady progress pictures in this thread kind of is a catalyst to keep me busy on it.

Its like on a woodworking forum I am on....I am self employed,....no one out there watching over me....I could go lay down in the corner and take a nap if I wanted...but posting progress pictures on the woodworking forum kind of feels like some eyes are looking over my shoulder and even though I dont need much motivation....it does make a differnence when I look at my progress...If I dont think I have really done much the last week ....I kick it up a notch.

Same way here with this Helicycle build...except this is being built during "sneak" away time from my stairshop.

Much more to come....:yo:

Stan

StanFoster

05-05-2009, 04:34 PM

I sealed up the inspection covers today. They have an 0-ring just outside the five bolts. I also put some sealant around the shanks of the five bolts...and under their heads.

The second picture is the oil pump cover that I decided was a LOT easier to safety wire now than later.

Also,,,those bolts coming through the tank sides....are held from falling back inside the tank by a safety wire until it is captured with a nut. If it fell inside...I would have to take the tank out...unseal the access cover...and go after the bolt. Would not be fun.

The tanks are ready to be bolted into place...and then the whole fuel system will be leak tested. I am trying to be very particular with each o-ring bolt...and I tried to carefully machine the inside of the tank at each location.

I should know soon.

Stan

All_In

05-05-2009, 05:47 PM

Looking Good Stan!!!!

No more disassembling? This is the final installation, right?

When do you get the parts back from the painter?

StanFoster

05-06-2009, 10:58 AM

John- I am playing it by ear on how many times I have to take the cabin off. It really is a simple thing to do even when completely finished. If I had a build thread to go visit like this one when I am done with it, I might be able to tell you if this is the last time my cabin is coming off. My painter hasnt called me, and I stay out of his hair. Stan

StanFoster

05-06-2009, 04:24 PM

All_In

05-06-2009, 07:16 PM

Oh I expected to see a picture with a lighter and an explosion?

Or at least a picture of a large pool of water?

But way to seal it!!!

Is the gas and lighter test next? We saw you practicing for it.

gyrodrifter

05-06-2009, 07:19 PM

Today was my fuel tank test day. I finished tightening the ten mounting bolts...put pipe plugs in the outlets...and ran vent lines so I know the air was out.....and then I filled the tanks up with water. I blotted down a little water that I had slopped....then moved the Helicycle to a perfectly dry area of my hanger....and went back to work on my stairway.

I was very apprehensive about the results as I let several hours go by. Had it been gasoline...I would have been looking in often...but water...no threat.

I kept thinking about how careful I was machining the inside of the tanks so as the o-rings would seat properly.....and yet was wondering what I could do next if I did have a leak. I just am not a throw a gob of leak-be-gone on it. I want it sealed right and without a bandaid fix.

My not wanting to look in the room reminded me of my character. I put off my colonoscopy for years....when I should have went in much earlier and had it done. I fear the unknown sometimes...and procrastinate.

Well....the end of the day came and I could not go home and wonder about it all night....so I went in and looked. I had 10 through bolts with o-rings that had to hold....7 fittings that were carefully sanded inside the tank that had to stay sealed.....and those two round access holes that each had 5 bolts in them. Lots of chances for a leak...but on the other hand....I was extremely careful and even a hundred holes should have held.

Well....after many hours....I took a peak...I looked at every bolt...fitting...underneath for the sign of a puddle...or at least one drop....and to my delight it was bone dry everywheres! Yip yip yahoo!:yo:

Had there been a leak,.,...I know how I am wired...and I would have dogedly pursued it until it was fixed before doing one more thing to my Helicylce.

With the leak test succesful...I am waiting on my floor seat pan to come back from my painters...so I can permanently bolt it into place...and re install my cabin.

No pictures....I will post some tomorrow showing the tank plates that had to be bolted on to anchor the tanks.

Stan

Good show Stan,

I can't see as to why you would be apprehensive about bolts going through your fueltank.:lol:

No way I'd like that either, I would probably find another way to satisfy my own apprehension.
I don't mean that to reflext on your integrity or your workmanship Stan, The design is what it is.

I worked with fuelbag lined tanks in Helo's and FW's, and at first thought that it was a dumb idea.
I mean why not just as easily build tanks that don't need condoms right?

Right...well now I'd be one of the first down at the supplier/manufacturer to see if I couldn't have one or two made to fit those tanks, no way ever would I feel good enough to trust that system, no offence.

I have seen and worked on wrecks with mostly everything bent, tore, toasted, busted and ripped off, but the bags in everyone of them were tight and still holding their fuel.
I'd bet my life on them.

To be fair though, I can't quite visualize your setup.
Are the fasteners embedded in pockets, or are they indeed thru bolted? Meaning from the outside to the inside of the walls.(Couln't be!)

I am only asking because I may have misunderstood.
In my mind I can't reconcile a setup like that, especially in a machine that holds most vibrational laws at gunpoint. (Again, no offence meant, I just don't feel good about the technological contradictions and compromises in a helicopter after having worked on them for a while, but I do love em.)

When I read and see pictures of how you do things, I've come to think that you are a very meticulous and careful individual who builds quality into everything he does.
It should make your machine a pleasure to fly when you're done regardless of what I think.

Take care Stan, Regards,:yo:
John.

StanFoster

05-07-2009, 02:33 AM

gyrodrifter

05-07-2009, 10:00 AM

John- The fuel system that B.J. Schramm designed for the Helicycle has been working very well. I have heard of a few minor fuel leaks....but I attributed that to some non attention to the thru bolts. The bolts are a very strong way of anchoring the tanks..and they have an o-ring on them.

You have to consider the complexities of keeping the fuel close to the cg of the helicopter...which means wrapped around the rotor driveshaft. You just cant hang a rectangle tank on this machine as it has to get maximum volume inside the frame. Thats why the tanks are cleaverly molded around the round frame rails.

I just had spent so much time trying to not have a leak....and would have been disapppointed had I had one after all that effort.

I will take pictures today of the seperation plates that have bolts going through them....

I just will leave the water in the ship for several days until I have to put in the elbows that connect to the fuel pump and vents.

Stan

It makes sense that way Stan,

I'm just being very "Dutch" this week.
Just ranting on overdrive :rant:

I guess there's time related inspections on everything for the machine anyway, and I'm also sure you'll keep an eye on the areas in question.

Gasoline may leak sooner than water, but I'm sure you know that also.
Just keep that methane gas lighter handy, you never know :D

Build it and it will fly,

Regards,
John.

StanFoster

05-08-2009, 05:46 AM

Kevin_Richey

05-08-2009, 01:23 PM

...sitting there trembling for its next flight. Plus, I dont even have to think of who has been sitting in it, dragging wingtips across its windshield, pulling planes out in front of it and blowing dirt all over it! I have the best situation for storing and maintaining my helicopter that I can imagine. I am looking forward to next years many flights in and out of my woods. Stan

Just like the Batmobile kept in the Bat Cave, your Helicycle is safely in your "Wood Cave". If you call it "Stan's Stair Shop Cyclone", or "Stan's Stair Shop Tornado" (refering to the tornado visits to your shop and woods), and put your business name, or logo, and contact info on the body, wouldn't you be able to write it off as a business expense for advertising?

Ditto for the expenses of helicopter flight training to learn how to fly your advertising?

gyrodrifter

05-08-2009, 01:47 PM

John- Of course whatever we fly needs constant attention to all the parts . A helicopter has more stuff to attend to, however the feedback from the Helicycle guys has me hearing its not that much to it. The number of them flying and the hours they are accumulating is impressive. In my case, with my chopper parked right in my stairshop, I will enjoy "looking" it over almost everyday. That will be a pleasure to keep it all adjusted, checked over, and sitting there trembling for its next flight. Plus, I dont even have to think of who has been sitting in it, dragging wingtips across its windshield, pulling planes out in front of it and blowing dirt all over it! I have the best situation for storing and maintaining my helicopter that I can imagine. I am looking forward to next years many flights in and out of my woods. Stan

Stan,
You have a good thing going there at the shop.
I just watched a Helicycle video, nice looking machine, and I like the turbine hanging under it, you are indeed going to enjoy that machine.

What make of turbine is it? you wrote the name of it in a previous post somewhere but I forget the brand. Does it fire from a single annular can? or is it a different setup?
I'm just guessing but is it also a free running second stage for the power takeoff? or is it set up like a small APU type turbine with a direct gear reduction for power take off?

Thanks,
Take care, John.

StanFoster

05-08-2009, 02:04 PM

John` Its a Solar T62-32 turbine. Single stage...with an electronic FCU. Centrifical compressor....basically just one moving part...but does it move.....

It will run at 61,500 rpm....

I just bought a new camera....and these are my first pictures with it. I had is set on the lowest resolution...only around 40k. I will up the resolution next series of shots. This camera will go up to 12 megabytes.

Here are some more pictures of the tank separation plates. Also...I am hooking up the vent lines...and all the other fuel plumbing.

I forgot to mention that I strayed from the plan....the build videos show using white teflon tape for the fittings. I did some research on it and it should have been the yellow kind. It states on the yellow that its good for gasoline, kerosone...etc. I went ahead and used the paste type also...I just feel it seals even better.

I will be waiting on my floor/seat pan to get back from my painter....and then my third shipment with all the wiring and instruments.

Stan

gyrodrifter

05-08-2009, 06:39 PM

Stan,

I just went and checked out the T62,

That's a nicely laid out engine, pretty compact and it looks like the hot section is separated from the PTO case by the compressor intake, it makes me think of some of the APU engines I worked on.
Most of those were single stage centrifugal ones too, some were surplus military units and some were out of cargo planes as redundant power sources.
The plan was to design them into other applications, but that never took off.

What kind of fuel choice are you going to use Stan? JP4 will probably give you the biggest bang for your buck, but I wonder if it would run hotter then Jet A or Kero, not sure about gasoline, that's pretty volatile/flammable compared to the fuel oils.

I think I'll buy the first support group attendance ticket (that'll pay for your fuel), I'd like to be there when it spreads its wings for the first time.:D:D

It'd only take me about 14 driving hrs to get down there, it would be worth it.

And if I could be down there for a few days, maybe I could throw in a few extra hours on gyro if I could find a CFI with a machine nearby.
All good thoughts.:D

Take care Stan,

John.

StanFoster

05-08-2009, 08:18 PM

John- JP4 would be the fuel of choice.....kerosene will be the fuel I buy in bulk. Diesel fuel from some farmer will get me there also...though it burns a little dirtier. I will stay away from gasoline...though I have read that low percentages of it work. I wont be the one to experiment. Kerosene from the home base...and JP4 at the airports.

Stan

StanFoster

05-09-2009, 02:50 PM

I went out to the shop this morning and found very small puddle of water under one of my tanks. I went....:eek:

Closer look found it was just one of my brass pipe fittings that a quarter turn fixed the leak. It remained dry the rest of the day.

The middle picture shows a couple of thru bolts that are doing their job without leaking. Those bolts will get another locknut on them, plus a little locktite as well.

Stan

StanFoster

05-11-2009, 04:19 PM

My floor/seat pan is going to be done Wed.....so I went ahead and hooked up my cyclic and collective control rods.

I put the walking beams in that are all now painted....it feels good to start putting this ship back together.

The controls feel nice, tight,..and with a smooth resistance.

You can see my fuel line that is just connected right now across the two tanks. I have the tanks full of water and just letting them sit for a long test. So far....not a drop has leaked since I tightened that one fitting.

The control rods going up to the walking beams are just temporarily bolted in place....I am not 100% certain of the correct order they go in. A quick check of my build video will see if I have it right.

Once I get my seat/floor pan back installed...that means the instument pod goes in, followed by the cabin. I will then be at the mercy once again of awaiting my next shipment. The next shipment is due anytime and will have all the wiring and instruments. I feel this part of the build will be the most intersting so far.....and it will keep me busy till the turbine arrives.

Stan

Stan

StanFoster

05-12-2009, 04:52 PM

This video is not the most exciting to watch,,,but just shows the cycic mixer going through its left and right cyclic inputs....fore and aft inputs....then a circular combination of both. I should have operated the collective showing how it simply raises the mixer.

http://www.youtube.com/watch?v=qMVVtsK2YLE&feature=channel_page

Stan

All_In

05-12-2009, 05:05 PM

Very cool Stan, but you cut the audio out of you making engine noises, why?

StanFoster

05-12-2009, 05:09 PM

John- I cut the audio out as I didnt want to hear the grinding and clunking sounds my "s-m-o-o-t-h cyclic makes. Its better to just say its smooth....ha:D

Stan

Passin' Thru

05-12-2009, 05:21 PM

Very cool Stan, but you cut the audio out of you making engine noises, why?

Come on Stan, we all know how to make piston engine exaust noise, show us how to make turbine noise!:lol:

JEFF TIPTON

05-12-2009, 06:04 PM

Let's see: for turbine noise one air gun blowing on one used ball bearing rotating at high speed. That should work!

All_In

05-12-2009, 06:07 PM

John- I cut the audio out as I didnt want to hear the grinding and clunking sounds my "s-m-o-o-t-h cyclic makes. Its better to just say its smooth....ha:D

StanYou crack me up!!!

Arnie Madsen

05-13-2009, 02:21 AM

Let's see: for turbine noise one air gun blowing on one used ball bearing rotating at high speed. That should work!
Jeff .... do you have a video cam watching me in my shop ? I would swear you have been watching me spin up bearings while I was thinking turbine sounds .....

Then I got thinking if I first washed the bearing in kerosese , spun it up , lets say 61,000 rpm , held a bic lighter behind it ....

.... the end result would be Fosters Inferno which I think is a better name than all the other recommended names for Stans oil burner.

Credits to John from Ontario for the name Fosters Inferno. He thought of it first.

In about 2 hours from now Stan will be scouting around the farm for an old bearing he can spin up with his DeWalt air compressor. Just to get him by until they ship him the real thing.

Good morning Stan , hope you have a nice day.

Arnie.

earthbnd misfit

05-13-2009, 04:20 AM

CAn you put a small amount of pressure in the tank to check for leaks?

StanFoster

05-13-2009, 04:21 AM

Arnie- I am having a beginning to another great day.....so thankful to wake up to another one! I like your "Inferno" name...... just so the inferno stays inside that turbine! By the way, my DeWalt router turns 30000 rpm...so I could record that noise. Also, the Solar T-62 turbine is completely taken apart, machined to close tolerances, new bearing, then it is super balanced. Balance is EVERYTHING at 61500 rpm....plus oil of course. Stan

StanFoster

05-13-2009, 04:34 PM

Received my floor back from my painter. I will bolt this in place....then put my upholstered seat covers in.

Stan

StanFoster

05-13-2009, 04:46 PM

I got tired of waiting for my turbine engine...so I went and mounted a DeWalt motor on my Helicycle. I am excited about this....it has 3 horsepower....and maybe it will fly in ground effect?

Here is a video link of its first runup.

http://www.youtube.com/watch?v=L9VLlrlopoo&feature=channel_page

Here are some pictures.....

Stan

Chuck Roberg

05-13-2009, 04:53 PM

I assume your DeWalt tool is out of warranty. I don't think the warranty covers this usage. :cool::suspicious:

All_In

05-13-2009, 05:02 PM

I knew about this but still laughing after actually seeing it!!

Good One!!!!

route66

05-13-2009, 05:15 PM

:eek:Hope your parts come in soon as I think you are loosing your sanity without them.:rapture:

Kandace

05-13-2009, 07:15 PM

Stan, You're silly!:hail: So how long of cord and what gauge do you think you'll need?

Kandace

ckurz7000

05-13-2009, 10:33 PM

Stan, what worries me even more is that you might mount your T62 turbine to some of your DeWalt tools. But I can't wait to see the stairs you'll turn out with this!

-- Chris.

All_In

05-14-2009, 08:54 AM

Please don't encourage him Chris!!!

JEFF TIPTON

05-14-2009, 10:23 AM

Chris I don't know if we would see the stairways from turbine powered tools. Too much dust in the air.

StanFoster

05-14-2009, 04:31 PM

I had a two hour window to work on this today...so I installed my cyclic control rods to the scissor arms....and installed my upholstered seat.

I am just about out of stuff to do before the next shipment comes.

Stan

NoWingsAttached

05-14-2009, 04:54 PM

how come there's only one seat? where am I supposed to sit?

utahgyrocop

05-14-2009, 06:31 PM

Stan,

I would bet money that right after the seat was in...you sat in it and moved the controls...you did didn't you?:whoo:

Arnie Madsen

05-14-2009, 09:20 PM

Stan

Your choice of colors has been excellent so far. I know you thought them out far in advance .... but you are correct on all counts. Very nice paint scheme. My opinion of course.

Choosing style and color in advance requires a visionary mind. You had pictured something that did not exist. Then you put your plan through a paint gun and it comes out as you first pictured it. Now we can all see it. Looks good.

To have a mind that thinks in such a fashion is one of the many facets of the Stan Foster we all like to follow. Somewhere within is a teaching we all benefit from. Thank you for that. Some may call it good planning , but I like the word visionary better. Not even sure if that is an actual word or not.

I have not even mentioned your properly painted Helicycle hovering down the Chopper Chanell you had cut open in your yard to get you out to clear sailing. Nor all the hours you spend cutting and glueing wood in your stair shop , probably paid for the turbine in the mail from BJ Schramm. You know what I mean. Havent even mentioned tornado's , and you painted it on the Helicycle. Talk about a positive way to handle strong winds in the neighbourhood.

Profound thanks for sharing your build with all of us Stan. To buy and build a helicopter is quite an accomplishment. To be able to plan everything out properly is quite rare. You have shared those things with us , and they are valuable lessons. I learn from you continually. And with envy I might add.

You probably will be reading this at 5:30 in the morning. May you have a kind and gentle day that goes according to plan. If not , you will handle it anyway. This I am sure of. Thanks again for the valuable lessons. Much appreciated.

By the way , the helicopter looks good too. Just thought I would mention that.

Arnie

StanFoster

05-15-2009, 12:18 PM

Heath- You were right on. I sat in it and the padding under the seat cushion fet real comfy....plus I put some foam behind the upholstery...and it feels extremely comfortable. The angle of that seatpan is just right for me....many times the seat sits too vertical.

Arnie- What else can I say to your kind words...but thank-you.

You were close on he 5:30 a.m. time that I read your reply. It was actually 5:05 but I was in a hurry to get to the helicopter...I mean the stairshop to make a living.;)

Stan

StanFoster

05-16-2009, 12:30 PM

I had a good Saturday to work on my Helicycle. Got out before 6 a.m. and installed my auxillary fuel tank. This would be a much larger job to install later.

I went and changed the hex head bolts for nice allen screws to hold the floorpan down.

Next came the instrument pod....and it was all secured.

Stan

StanFoster

05-16-2009, 12:38 PM

I decided to throw the cabin on with a few screws...plus trial fit it for any obstructions with the added cyclic controls...main fuel tanks...and auxillary fuel tank. No problems....so I took some photos.

Its starting to look more complete with the fuel tanks in..finished floor/seat pan and upholstery.

This machine is a lot of fun to work on.

Stan

StanFoster

05-16-2009, 12:45 PM

Before I took the cabin back off....I rolled it outsided for a photo session.

Thats a lot of work so far on it....but it has been a pleasure.

Stan

Kandace

05-16-2009, 01:32 PM

I get more jealous everytime I look at this thread! I want one of those little hot rods for myself.

Alas it will never be, I am but a CFI and as such don't make much, but at lease I love my job!

I was just thinking........don't you have 40hrs to fly off after it is done?

I volunteer to assist! LOL

Kandace

Ingi

05-16-2009, 03:22 PM

Hi Stan.
Wow! What a great looking helicopter!
"Strap on Helicopter!"
Amazing color selection.
Make sure you make room for this baby:) http://www.samsung.com/us/consumer/detail/detail.do?group=camerascamcorders&type=camcorders&subtype=highdefinition&model_cd=HMX-H106SN/XAA
Ones you go flying the "Cult" will need some in flight video :)

Best regards,

Ingi.......
Iceland
P.S I am waiting for my contract to me shipped to from the factory:)

ylf

05-16-2009, 06:13 PM

Looking good Stan! By the way, how did you end up with the aux tank, I thought they would only sell it to pilots under 180lbs.

Mike

StanFoster

05-17-2009, 04:45 AM

Mike: I bought the tank privately. I know the factory wont sell one. Mine will not be hooked up. Its in there because I got a good deal on it...and its a lot of work putting it in later. There are several my size running with this auxillary tank.....but it wont be connected at my checkout. I realie that if my helicopter is all setup for the standard fuel system....then this auxillary tank is plumbed in ....the CG will move forward....and the ship will have to be rebalanced and trimmed. That is way down the road in my experience....If I do hook it up.....the only time I will fill all the tanks is if I am wanting to do a long cross country. Otherwise...90% of the time I will not use the extra capacity.

Stan

StanFoster

05-17-2009, 04:52 AM

My cabin is back off for other stuff to install. This is the fuel shut off valve. The fuel pump , fuel filter are next on my list to sneak on this week.

The last two pictures show the color I am going to paint the instrument panel. These are the belly plates that will be screwed to the bottom of the cabin on final buttoning up. I held them up inside the pod to show the color scheme. I KNOW that the black gauges coming out of the burgundy panel plate will satisfy my eye.

Stan

All_In

05-18-2009, 07:11 AM

Wow, buddy it really does look SWEET!!!!

StanFoster

05-18-2009, 02:38 PM

Thanks John....

I installed the fuel pump before my stairwork began....then I installed the T-block plumbing fitting that feeds both tanks to the fuel pump. This T-block sits right close to the cyclic controls....and some of these are just fastened with plastic ties. I dont want anything coming loose and getting into my contols...let alone a fuel line! So...I just quick fashioned some U-clamps out of these adel clamps and bolted that T-block into place. The two fuel lines now have a secure place to be tied off to.

One thing I noticed about the Helicycle parts...everything so far has been high quality....and almost all the parts are stamped Made in the USA. Just like this fuel pump.

Stan

utahgyrocop

05-18-2009, 04:56 PM

Stan,

Your project is looking incredible, almost unbelievable,thanks for sharing.:whoo:

Just a question, after you get your helo rating, do you intend to get any turbine lessons before you start to fly yours?

I don't know much about turbines, but I would think at least a couple hours in say a small bell or something similar with an instructor would have long term benefits toward your investment. Not cheap at all, but is it necessary or worth it?:noidea:

Just curious. Keep up the good work!

Stay safe.

StanFoster

05-18-2009, 05:10 PM

Heath- Thanks! I havent planned on any turbine time. They are real thorough during the checkout...and since this is a single stage turbine....I just as soon keep all my energies learning its functions. I have been watching the Helicycle engine startups videos.....and the more I learn about this machine...the more I love it. I am not tiring of the build AT ALL....just tired of the down time waiting for the next shipment. I will soon be getting my instruments and all the stuff for the instrument pod.

I like the way the instrument panel will be wired out of the ship....then simply put into the pod with two plug in connectors wiring the whole thing. Its really well thought out.

Stan

gyrodrifter

05-19-2009, 07:20 AM

Hello Stan,

Just dropping in from the sunny North.

The H/cycle is really looking tasty!

I just know you're having a blast with it all, you truly are enjoying it at a calm pace I can tell.

I haven't gone anywhere, just doing the boats up and have gotten everything seaworthy.
Gained a tan and all :D

Keep at it Stan, sooner or later you will be turning that turbine over for the first time, and when you do, there'll be a hundred exited friends waiting to see
it start up just like it was born to do.

Regards,
John.

brett s

05-19-2009, 08:04 AM

There's no trick to flying turbines (just like anything else, stay within the limits) - the potentially expensive part can be screwing up when starting or shutting one down, one good overtemp & you're out a bunch of money.

StanFoster

05-23-2009, 02:22 PM

While I am awaiting my instruments and panel material...I started my panel layout. I am going to paint the panel that the instruments are installed into the same burgundy as the cabina and seat. I am considering all future additions...and I want to end up with a symetrical panel. I have the fuel flow meter incorrectly labeled next to my radio...it should have been the transponder.

I definately want the ASI and the rotor tach...both 3.25 inch instruments at top and center. The VSI, altimeter...and vertical card compass are clustered on the left....with the turbine oil/temp, transmission oil/temp, and voltmeter on the right clusted together. The lower rectangle panel will have all the switches and breakers...fuel flow meter...hobbs meter...chip detector lights for the transmission and tail rotor...

I probably will make a change before I do the final panel cutout. I am waiting for my Geo-pilot plus to come as it is the focal point of my instrument panel.

Question to anyone on that vertical card compass. I have seen these mounted right amongst other gauges in a dash..but is it hampered by magnetic interference possibly?

Stan

Stan

karlbamforth

05-23-2009, 04:32 PM

Hiya Stan,

Everything is looking good.

Vertical compass cards can be affected by other instruments. It would probably be best to keep it as far away as possible from electrical instruments, radio etc. Maybe swap places with the Alt. That way the pitot static instruments will be between radio/GPs and the compass.

This website offers shielding metal for vertical compasses.

http://www.wingsandwheels.com/page22.htm

Maybe its just me getting old but I did notice that they say you can "TRY" to block conflicting instrument and not that you "CAN" block conflicting instruments.

I have never tried it so cannot say if it works, just letting you know this product is out there.

StanFoster

05-23-2009, 05:09 PM

Ranger- Thank you much for that site! I have noticed some guys hang these on the outside like a regular compass...while others hang em inide with all the other instruments. I am thinking that maybe I will put it at the far left in the cluster....plus the altimeter and tha VSI are not electricically driven...and it will be farther away from the GPS. I will ask some of the guys that are flying with theirs to see what if any problems they have had.

I am still in the design phase before I do any actual cutting out. That saying that a job well planned is half done is so true.

Stan

All_In

05-24-2009, 07:57 AM

Hi buddy!

When I was a piper dealer with 21 new pipers on the flight line, it didn't take me long to make certain every aircraft I ordered was laid out in the same way.

This enabled our students and myself to transition from one bird to the next without interrupting their learned IFR instrument scan. I beleive it made our students safer!

If you try an match the R-22 your going to be leasing it will really make it easy to transition from one to the other.

Just a taught?

PS:
I'm so jealous, you're having so much fun building your dream, thanks for sharing it with us. It's the next best thing!

StanFoster

05-25-2009, 03:24 AM

John- The R22 panel and the Helicycle panel have different geometric shapes...and the instruments cant be put in the same.

I like the fact that the instrment panel plugs in..so that you aren upside down stretching wires...trying to hook something up. It all easily comes out and over to the workbench. Plus you can easily change your panel layout should you need to. I am trying to get it right the first time so I will be done with it. If say I dont put the transponder in immediately...I will have the space set aside for it for future installation.

Here are some nice videos off of u-tube of some of the Helicycle guys. These videos say more than anything to me. Many myths dispelled in these videos to me....plus there are some questionable flying also in regards to the HV/curve!....but thats them not me!

Like any other group...they are very close knit and love their way of flying. Thats what it is all about....

http://www.youtube.com/watch?v=yk1kyeQixC0
http://www.youtube.com/watch?v=BNuW6Bfx840
http://www.youtube.com/watch?v=HGTXVE3c07o
http://www.youtube.com/watch?v=izUoAz3SlfQ
http://www.youtube.com/watch?v=80S4Li5DivY
http://www.youtube.com/watch?v=nyHIjgwqAyY
http://www.youtube.com/watch?v=tGsncUuhRe4
http://www.youtube.com/watch?v=3q0-nsSUlVs
http://www.youtube.com/watch?v=1YyYHTNKbn0
http://www.youtube.com/watch?v=eZ97oDDM2ko
http://www.youtube.com/watch?v=CO5HLRAqSB8
http://www.youtube.com/watch?v=CO5HLRAqSB8

Stan

animal

05-27-2009, 02:00 PM

HI Stan. thought you would like these pics.

AS you know I have a back yard landing pad. has not been repainted in several years.

decided to break down and repaint it.

funny thing right after I repainted it 3 206 jet rangers flew over.

Now all I need it that Helicom Commuter Jr. helicopter and I would be set.

Well yeah I do still need to cut down some more tree's that grew back up in the swamp, but hey a few hours with the chain saw takes those down.. :)

What ya think Stan?

StanFoster

05-27-2009, 04:28 PM

Tim- Looks good. The ol H-spot!

Stan

animal

05-27-2009, 04:33 PM

I figured you would like that Stan. :)

StanFoster

05-27-2009, 05:00 PM

Tim- What kind of approach and departure area do you have after potential clearing of vegetation? I made sure I wasnt going to be doing max performance takeoffs out of my woods just because it can.....and just because that one Helicycle pilot was doing it in one of those U-tube videos I posted.

I would like to say that I will rarely do one...even though it was common practice in my R22 training to lift right out of that hole by my stairshop....and NOT use the chopper channel! I mentioned to my instructor....and even promised him that I would not be climbing out over treetops just clearing them by 20 feet or so.....and totally relying on an engine and or its supporting devices to keep me out of those trees. I would like to see my wife again after each flight!

Thats why my chopper channel is so important to me.

Stan

animal

05-27-2009, 05:08 PM

Stan I use to be able to sight over the trees at a 30 degree angle, the cut out will be 75 feet wide and over the swamp,I will make a banking climb out over the creek bed. it is pretty clear. just right now there are a bunch of small trees that block the approach and departure area. the ground drops down just past the pad where that tree line is. also just over the back tree line the neighbor has a big field,should I have to set down. we have had a TH-55 Hughes back in here before.

lanichol

05-27-2009, 07:42 PM

Stan,

Do you have the fuel flow sender in hand? I would like to know the brand/model, and how it plumbs.

StanFoster

05-28-2009, 02:37 AM

Larry- I dont have it yet. I am awaiting the instruments that they supply...then I will order the rest. Several are using the JPI FS 450. I havent made up my mind if I will have a fuel flow meter for certain. I have only talked to one that has used this fuel flow meter....and he was happy with his. Then I just read on the Helicycle Builders Group forum that someone was having interference problems in the 120 mhz range. I am still researching before I put one in. I am not putting in any type of fuel level instrument however....I am planning on a good ol sight gauge calibrated so I can see when that turbine is down to 2 gallons. The fuel flow meter would be nice...but it would be verified with a quick glance at my sight gauge! Its like my laser lever in my stairshop....its the most accurate instrument I have...but I still verify it with a simple ol plumb bob!

Stan

StanFoster

05-29-2009, 05:51 PM

I requested my instruments, wiring....and instrument panel material be sent to me early....and it arrived today. The rest of the third shipment will be other various parts....the swashplate...rotorhub and blades.

I now have quite a bit to do.....so back to some build pictures again.

Here are a few pics of some of the instruments. They have the Helicycle name on the faceplates.

Stan

utahgyrocop

05-29-2009, 07:57 PM

I now have quite a bit to do.....so back to some build pictures again.

Stan

Boy am I glad, I was starting to have withdrawls from no progress...:D

It is looking great, Stan, keep up the progress, it is uplifting.

Stay safe,

trunkmunki

05-30-2009, 09:18 AM

Just curious,

How do you gauge the power on the Helicycle? I know it has been "derated," but there doesn't seem to be any torque meter. Just looking at TGT seems like it would be too variable with environmental conditions, unless you just set a very low limit that under all circumstances would be below the drivetrain maximum. Even then, as the engine wore out it would seem like the TGT would get higher, or power lower, over time.

asmuzsr

05-30-2009, 11:25 AM

StanFoster

05-30-2009, 01:44 PM

trunkmunki- Good question on the absence ot a torque meterm B.J. Schramm in his keep it simple ways, has us keep the drive belts tensioned to a certain amount. Pull too much collective and the belts will start slipping. I have listened to Helicycle pilots talking about tightening up their belts to get 110 mph or a high rate of climb, but B.J. would have frowned upon that. He specifically designed the transmission to last 2000 hours and he set the tension standards on the transmission to make those numbers. So, if I wanted to be foolish, all i have to do is tighten the belts up like banjo strings and I could have a hotrod performer for sure! But the Helicycles performance is impressive enough. I think cruising at 95 is plenty enough torque that B.J. has the torque limiter set at! Stan

StanFoster

05-30-2009, 04:44 PM

I have been asked a few times about how hard the cabin is to put on and take off. It is real easy....but I used to think that would be a pain. I had to put the cabin on this morning so as to center my instrument pod inside.

Here are some pictures of it going on.....just a few screws holds it right now...the final button up will have all the screws installed.

Stan

StanFoster

05-30-2009, 04:53 PM

This mornings mission was to make a template that fits inside the instrument pod.....scribe it to fit so there is an even depth.......then transfer this profile to the actual aluminum panel. You can see where I wrote adjustment measurements on the luan that I initially fit. I beveled the edges of this luan so as to give a precise fit...then marked on it where it would need a tad more material. I had some places that needed a 32nd ......some places that needed a 16th.....and one place that needed an 8th inch.

I traced this outline on the aluminum...then added my adjustments...and faired the curves through these points.

I was pleased that it fit real close the first try....with only a little sanding to get the depth correct.

Stan

StanFoster

05-30-2009, 05:04 PM

Some more pictures of the aluminum panel getting fit into the pod.

I forgot to mention that I am a stickler about wiggly instrument pods. Even though the design of this pod feels real strong......see where that wood space block is at in the last picture? I am going place a round section of hard rubber between the pod and the cabin on both sides....this REALLY locks that panel in....and it even reinforces the cabin. Plus.....it guarantees a nicely centered instrument pod. It is very hard getting that centered...and just tightening up the bolts differently can change it either way. The rubber blocks will have a small threaded screw going through it and into the pod.

The lower rectangle panel will contain the switches and breakers...and any overflow guages. I am still contemplating my instrument layout. It will be symetrical....and will be designed around my Geopilot 11 GPS.

I love the way B.J. designed this instrument panel so it just unplugs and comes out of the ship for wiring...modification...service..or whatever. Well thought out by him in my opinion.

Next I will attach aluminum angles inside with rivets. These will also have rivnuts attached to them for the panel screws to attach to.

After all my holes for the instruments...breakers...and fuses are made...these aluminum panels are off to my painter to be sprayed the same burgundy that the cabin has on it. The burgundy panel will be a good combo with the black instruments.

Stan

StanFoster

05-31-2009, 05:12 PM

Not earth shaking news....but I am chipping away at getting my instrument panels secured with riveted angles and nutplates. Lots of fun msc. fabrication that gets me a step closer to liftoff...:)

For those that havent installed nutplates...there is an easy way to get these exact the first time. I find a drill bit that just slips through the nutplate..in this case it was an 1/8 inch bit. I layout out the perimeter mounting holes and drill with this smaller bit first. This assures that later when I drill the 11/64 inch panel holes...they will be dead center with the nutplates.

I take the 1/8 inch bit and drill through the instrument panel through the aluminum angles that are riveted on. Next I just place the nutplate on the bit and drill one rivet hole...place a rivet loose in that hole to align it...then go drill the other hole. The rivets are pulled...and voila....one nicely centered nutplate. I then drill the instrument panel out as well as the aluminum angle...so that the screw can freely get to the nutplate.

I dont mean to go on a rant on something so basic....but I know at one time back when I was just starting using nutplates on my SparrowHawk....that I wish I had known this!

Stan

StanFoster

05-31-2009, 05:17 PM

Here I am showing the long aluminum angles that I had just riveted in. I used a depth gauge to set these to the proper depth so they will mate up with the upper panel nicely. I have the nutplates to install next build session.

I am still wollering around the instument selection to go into my panel.

Stan

earthbnd misfit

06-01-2009, 02:44 AM

Have you considered using a random orbital sander on the ali, to give it a rough anti glare finish, or are you painting it?

StanFoster

06-01-2009, 04:33 AM

Earthbnd- I am going to random orbit sand it, but just to get rid of scratches. Its going to be painted the same burgundy as the cabin. I feel this will be a nice look with the black instruments, switches and breakers cut into the burgundy panel. I am also going to wrap the front edge of the fiberglass pod with some black channel rubber. I am still researching what instrments I am going with, and whether I will double up on some instruments. Every Helicycle panel I have seen is different. I just want a clean, functional, and symetrical layout. So.......I am in no hurry cutting my holes. As you can see by now, the longest part of the Helicycle build is the wait between shipments. But I got to say, the quality of the components they send is worth the wait. Stan

animal

06-01-2009, 05:05 AM

Looking good Stan. glad the body is easy to remove and reinstall. makes things alot easier to work on.

StanFoster

06-05-2009, 06:12 PM

I received my airspeed indicator and had to figure out the max height I could cut it into my panel and still have a little clearance. It had a deeper projection than my rotor tach...so I will use this measurement for both. I used a bevel gauge and went up inside the pod and behind the instrument panel ....then set it to the exact angle that the panel meets the inside of the pod.

The bevel gauge was then layed on some posterboard and traced . I drew the instrument panel on it....then held the airspeed indicator onto my panel layout.....and postioned it to touch the inside of the panel. I could easily place a small square and check to see how much clearance I had. I moved it up so it had roughly 1/4 inch clearance....

StanFoster

06-05-2009, 06:18 PM

I needed to keep the centerline of these two insturments 2 and 3/8 inches down from the top...so as they wont hit when inserted into the panel. The ship is level in my shop.....so I made a plumb line to square off of for my horizontal line. Things were looking good....so I centerlined the next row of instruments.

The last two pictures are my upper and lower panel layouts.

I will be cutting out some holes next.

Stan

All_In

06-05-2009, 10:15 PM

animal

06-06-2009, 09:10 AM

I just realized. If I cut and paste your build posts with a little rewrite, print out a pamphlet regarding how to build a helicopter, I COULD SELL THIS!

But the blue pin striping tape, is not up to your quality of workmanship, and not a keeper??????
aw come on John, at least he used tape. I am guessing you are refering to the Panel. I just marked mine off with a Pen. one of those well it looks even to me kind of deals. not like we are building air craft or anything..oh wait I almost forgot ,we are building aircraft..lol

Hey John, when are you going to join the fun and start building? or buy a Gyro?

I know where there is a nice falcon project for sale.. ( shameless plug.) :)

Stan, the Helicycle is looking great,wish my Gyro looked half as nice.

I know why you opted to have the helicopter painted by a pro, seems it is taking me as long to complete the body work and paint on the Falcon as it did to build the rest of it. going to clear the rudder here shortly, but got to respray the H stab. wet sanded to much and got down to the primer.. :(

StanFoster

06-06-2009, 06:27 PM

I have been measuring each instrument and recording the actual hole size needed. The guy at Aircraft Spruce told me to just get one size for the smaller gauges...and one for the larger. I said..."What?" I just ordered an adjustable hole saw anyway. I have several different sizes of holes to bore...and one size would not work satisfactory for my gauges. For instance...that first picture calibrated out to a 3 3/16 hole. A 3 1/4 inch hole would have been too sloppy. The rotor tach instrument comes through from the front...and it only takes a 2 7/8 inch hole....but the exterior of the rotor tach gauge will look like its the same size as the ASI since its flanged is on the front of the panel. Same situation with my smaller instruments. The behind the panel ones take right at a 2 1/4 inch hole....but the front mount take a 2 1/8 inch hole.

Stan

dennisu

06-07-2009, 09:53 AM

Stan

Why not use the fly hole cutter that BJ suggested? I got mine for about $15 so they are cheap enough. That way you can cut any size you want without having the trouble of the hole saw wandering and making a bigger hole than you planned. Also good for making "plugs" as well as "holes" as the cutters are reversable.

Dennis

StanFoster

06-07-2009, 03:20 PM

I used my hole cutter from Aircraft Spruce yesterday to cut my panel out. That is a very accurate tool. I used it on scap to get the holes real close.

I installed the nutplates on the lower rectangle panel and have it all in position now. Next I will be laying out the switches/breakers.....and warning lights into the panel. I am going to wire a bank of ten switches with a few spares already to go should I add anything later.

The GPS will go in the center of the panel. That instrument has always been the heart of every gyro I have flown.

The last two pictures are the lower rectangle panel being nutplated in. That lower plate literally locked the instrument panel rigid. I couldnt believe it...and the screws arent even tightened yet.

After both panels are finished with the breakers...switches...and warning light holes....its off to the painter to have them painted the same burgundy as the cabin. I will eventually have some very neat white lettering identifying the switches....warning lights.

Stan

animal

06-07-2009, 03:27 PM

looks good Stan. those cutters like that really make the chips fly.

All_In

06-07-2009, 06:20 PM

@Tim
If I was looking for a cabin class gyro I would buy yours Tim!!!

@Stan
Your layout really looks good Stan, this is getting exciting. We need more parts!!!!

dennisu

06-07-2009, 10:26 PM

Stan

I see you are using a hole cutter and not a hole saw. I was thinking you were going have a real disaster on your hands if you tried to cut the panel with a hole saw as you said.

Dennis

StanFoster

06-08-2009, 02:38 AM

Dennis- I am perplexed as to why you think using an adjustable hole saw would have ended in a disaster? My last three rotorcraft had panels I had cut out with my adjustable hole saw, and the various instruments all fit fine! I ordered this cutter assuming it would be easier and even more closer tolerances, and I assumed right. Hey, I still have 2 holes to cut.....I can use my old adjustable hole saw if you want.....ha, Stan

dennisu

06-08-2009, 10:26 AM

Stan

You must know a secret that I and many others I know don't. I have tried both and the hole saw always started to wander once the teeth on the saw portion of the device touched the metal because it provided a tremendous amount of torque due to the surface area of all those teeth touching at the same time. The drill in the centre couldn't hold it centred with the cutting flukes on the drill enlarging the centre hole. Always ended up with a hole at least 1/8 inch bigger than the saw size. Seems the fly cutter type just makes more sense.

Dennis

StanFoster

06-08-2009, 11:59 AM

Dennis- My adjustable hole saw had three arms coming down 120 degrees apart. These arms have just a few teeth....it wasnt a whole circle of them like the fixed hole saws plumbers use. I also extended the pilot bit and had a block of maple underneath. Once that pilot was in the maple a good amount, the T cutters make contact and saw out a nice hole. It cuts nice holes, but it takes a lot of finesse to get real small changes if desired. The fly cutter definately is quicker, but I still would have had a usable panel with my old saw, just would have taken longer. By the way, how far along is your build? The waiting for parts is the hardest....but just thinking about flying this little beast makes it worth the wait! Stan

HobbyCAD

06-08-2009, 12:22 PM

You must know a secret that I and many others I know don't.

It ain't no secret Dennis. It's plain first principal good engineering practises. To start, use a reputable brand bimetal holesaw, not the cheap chinese sets. I only use Sutton or Starret. Every diameter holesaw has it's own optimum RPM to cut at, to get the same radial velocity at the cutting teeth. Use the correct cutting fluid. Clamp the workpiece. Cut into a block of wood, pilot hole into it first. Don't force it, with force, you can break your finger off in your butt !! Extract the saw regulary, clean the teeth. I've never had problems.

For aluminium, have you ever tried using violet methylated spirits as a cutting fluid? It makes a saw or drill go through aluminium like a hot knife through butter, and absolutely no galling. I can tap holes without problems.

Regards,

Francois

StanFoster

06-08-2009, 02:04 PM

Francois: Good post... I knew I wasnt the only one that drilled panels with hole saws!

Stan

dennisu

06-08-2009, 05:38 PM

Stan

I have 100% of my parts and am at 99% of build. Just the panel to finish and a few minor things and then the final assembly. Just ordered the new teeter bearing assy. from the factory so will have to do the head mod. when they arrive. Of course there are a few thing that have to be left loose for Colin to adjust when time for a checkout. As I said with 99% done that only leaves 50% left to do ......................

animal

06-08-2009, 05:41 PM

dennisu

06-08-2009, 06:19 PM

StanFoster

06-08-2009, 06:39 PM

Dennis- Thats a nice looking ship you have! Feel free to post more pictures here, but it would be nice to have another Helicycle thread going. There are a LOT of helicopter lurkers on this site as many pm . Stan

PalmPilot

06-08-2009, 07:51 PM

Nice ships, ... Stan, how long till you're ready to pull pitch? ... Your thread's to long for me to go back to the beginning. :sorry:

Mike

animal

06-08-2009, 08:44 PM

Animal

My ship is more of a work horse than a thoroughbred like Stan's. I have a bunch of pictures but more for reference and comparison and not for display and I don't want to clutter up Stan's excellent build thread. That being said I will put a picture on here of the ship.
still looks good to me. very nice. do another thread with more pics, will be nice to read about your tests and flights.

All_In

06-09-2009, 07:08 AM

Looking good Dennis!!! Thanks for sharing, we would love to see more...

StanFoster

06-09-2009, 07:37 AM

Mike- I dont know when it will be ready to fly. Too many things out of my control. The Helicycle is shipped in 4 shipments, thats so they can run batches of 40 at a time. This keeps the price low, the quality high, and the wait long. If however it was sold in one shipment, I figure it could be built in 6 months. I was averaging 100 hours a month with my SparrowHawk kit, and had it flying in 5 months. Thats not nothing to brag about because Steve McGowan built his in MUCH less time, and did a beautiful job as well! I have less than 300 hours in it, so that shows me that the 16 months I have had my project has been looking at it! When I received my 2nd shipment last winter, I actually didnt touch the parts until my new room was done. I figured I still would get caught up and waiting, and I was correct. When I get started on something, I dont pause until its done or I am out of material. The wait is worth it as they do a beautiful job on their manufacturing....I was very aware on the wait on shipments when I signed the contract and sent my money. So....I just have to live with what I knew and agreed to! It will be worth it all when that turbine first spools up......and I am not even going to go there about flying that thing. Stan

PalmPilot

06-09-2009, 09:46 AM

Stan, I know the construction and anticipation is sometimes half the fun! You seem to be a true craftsmen, and it shows!!!

Mike

StanFoster

06-11-2009, 02:01 PM

Thanks Mike! I am really enjoying the build. Actually this build is very relaxing not having all the parts sitting in the corner begging to be installed.

I drilled the switches and breakers for the lower panel. I have the turbine tachometer to cut in right above the switches. There will also be red and green clutch lights....chip lights... later added in.

Stan

StanFoster

06-13-2009, 04:30 PM

Today I fabricated my pitot tube...installed it along with the static port.

It goes through a steel disc and then is soldered to that. Nutplates were installed and the pitot tube bolted on. I am going to have this painted burgundy as it falls in that color band underneath.

The pitot tube is 1/4 copper pipe which was easy to conform to the blueprints as in the picture.

The last picture is the static port which I riveted into the belly as per the location called for on the plans.

Stan

StanFoster

06-13-2009, 04:40 PM

After the pitot tube...I had to cut out for the turbine tach. I just placed the panel on a 1/4 luan scrap on my table saw...and raised the sawblade up through it. This cuts a nice square hole.....and that was done.

I then placed it back in with more breakers and switches so as to look like I am getting something done today.:yo:

Stan

StanFoster

06-13-2009, 06:00 PM

I have been leak testing my fuel tanks for going on two months now...they are full. The first picture shows one of the ten tank bolts with an o-ring that seals them. Some time ago....one of the upper ones developed a very slow seap....so this was put on my back burner until today.

I took the bolt out and put a new o-ring on it...fished it back inside the tank with a wire...tightened it up and filled it back with water. Still was seaping.....so I tried a slighter fatter o-ring and same results.,.. a very slow seap.

I had made a tool for grinding the inside of the holes for the fuel fittings...and I decided I would have to make a special tool for sanding the inside of the tank where the bolt and o-ring seat against. That one place must not be perfectly flat...has a micro groove...or something.

So....what I have is a 5/16 hole coming out of the tank. I decided to take a 3/16 inch bolt and make my tool with that. I had to take a die and thread the bolt about another 1/4 inch. I then tightened up three 10-32 nuts all the way down on the bolt. Next came my lathe...which is just my hands spinning this assembly of nuts parallel against a disc sander. I milled these down until they just fit nicely down a 5/16 hole. Now I have a bushing to guide my sanding appartatus.

Next I tool a fender washer and placed some self sticking sanding paper on it. I trimmed this down to the outside edge of the fender washer. This sandpaper side will go inside my fuel tank...the bushing end will protrude out the hole where a drill will chuck on and mill the irregularities out of the inside of the tank through the action of the sanding disc grinding the surface flat.

You can see I cut the bolt head off and drilled a 1/16th inch hole in the end. That is where a length of safety wire will be tied to the tool...and pulled into the inside of the tank....and out the hole that is leaking.

This is as far as I got today. Next episode will be fishing the grinding tool inside the tank...out the hole....and grinding away. I am expecting no leaks just like the other 9 are behaving. I must have a rogue blemish right where this hole is. Hopefully my blemish grinder will end this leak.

Stan

ylf

06-14-2009, 06:55 PM

Stan,
Are you going to attend Homer's this July? I realize your Helicycle won't be ready, just wondering if you are going. I just booked my flight and room yesterday, looking forward to seeing all the completed Helicycles.

Mike

StanFoster

06-14-2009, 07:04 PM

Mike- I definately am going to Homers again. I hardly left the corner where the Helcycles were parked when I first went last year. A year ago I thought maybe I would be flying by now....but next year I plan to fly there in my chopper.

Stan

StanFoster

06-15-2009, 03:44 PM

I received my AvMap Geo-Pilot 11 plus GPS today. I just plugged it into the cigarette lighter....and snapped a picture. The screen is much higher resolution than the interference patterns that come up here. The pictures of the display are horrible....but you get the drift....

It is the perfect size for my instrument panel. I am going to neatly recess it...probably make a sunken box with velcro strips on the back of the unit. I have installed all my GPS's that way...it looks like its built in..but you can just give it a good tug and out it comes so the memory card can be updated or whatever.

This screen can have whatever information you want displayed. I usually zoom in a lot more. It displays all the towers and gives you a warning.

I like the checklist part also. It wont let you move on until the boxes are checked. This little gadget works perfect in a helicopter. Another thing about this is it is live radar capable should I want to subscribe to that service someday.

Stan

Chuck Roberg

06-15-2009, 04:57 PM

That looks good Stan. I'd like a better unit myself. But to pay for it I'd have to back to work.

Did it show the Presidential TFR's up north of you today? :D

StanFoster

06-16-2009, 02:17 AM

Chuck- It will show TFR's if I get over my cheapness and subscribe to it.

Hey, Thursday or Friday when you and Jim fly down to Paxton in the SparrowHawk, I will give you two a free stairshop tour. These tours are normally $100 but free to friends....;)

Stan

All_In

06-16-2009, 07:29 AM

Looks good Stan.

Going to have to wait for the pictures of the mounting, not sure from the verbal description, exactly how you're mounting it.

Chuck Roberg

06-16-2009, 10:30 AM

Stan, I was checking the forecast. It's looking like scattered T-Storms. So we might have to put it off till next week. If we're coming thurs or fri I'll call before we leave.

Jim's Sparrow Hawk is temporarily down. The end of the flex shaft that fits into the Bendix came apart. Called Tom and he will have a new one ready for Jim later today. Talk about "Fast" service.

StanFoster

06-17-2009, 06:24 PM

I took a little time today and inlayed my GPS into my dashpanel. I traced around the unit....then cut out real close with the table saw....then finished up with a dremel tool....followed by a file until the GPS squeeks as its pushed into the hole. I will file it just enough so its just slightly tight....then I am going to rivet on some U-brackets off the back of the panel. There will be some velcro strips holding this in place...but I will be able to pull it out of the dash if I wanted to update the chip,....or put in the U.S roadmaps and use it in my truck.

I tested this unit out while driving to Peoria yesterday and this thing does far more than I will ever ask of it. It has an unbelievable amount of information available ....but most of it I will leave off.

When I am done riveting in the U-brackets ....its off to the painters to get sprayed burgundy.

Stan

Kandace

06-17-2009, 07:05 PM

Hi Stan, The quality of your workmanship is absolutely wonderful! And the ingenuity you display is fantastic!

Kandace

StanFoster

06-18-2009, 05:00 PM

The GPS is all installed....and can easily be removed out of the dash. Its a snug fit and the U-bracket with velcro secures it.

I am running a switch/breaker circuit for this GPS. Should I have low voltage problems...I can just switch the GPS circuit off and restart the GPS with its internal battery.

Stah

animal

06-18-2009, 08:29 PM

once again Stan you have out done your self, that is a very nice and clean panel.

Arnie Madsen

06-18-2009, 09:31 PM

I never paid much attention to your panel assembly until now, I like the way you blacked out the inside of the cockpit. Everything important on your panel looks clear and crisp.

Even when there is blue sky outside the lexan , your panel should be easy to read.

Arnie

StanFoster

06-19-2009, 08:01 PM

Well----I try to tell it all ...good and bad. I had a small setback...-that o-ring bolt I was trying to stop leaking...wasnt leaking after all.

I got suspicious after 5 or 6 attempts to stop the drip that took 6 weeks to develop. I lowered the water level 3/4 of an inch below the hole and it still was dripping! I called the factory and they said it could be a rare pin hole...and it would be easy to fix. I would have to remove it as it was leaking where the tank was molded around one of the round frame tubes.

I had to remove the cyclic and collective control rods...drop the bottom tanks out....drop the transmission and rotor shaft to get to the top tank. I found it had a small split in it. The split started where a weld was a little bigger than it should have been....smooth...but too big. So hindsite says I should have filed those welds down....and foresight will see me doing just that before the next tank leaks. These tanks are real tough and they have had very little trouble with them. Maybe mine was just a quirk and had a thin section right where it was pressing against the weld.

Its weird that it leaked in the shop....instead of after the ship had been flying for 20 hours. I have to look at this as a positive....it could have been a BIG nuisance to have to do all this...and drop the turbine and who knows what else to get that top tank out.

I do not want a repaired tank...as this is too much work to be saving a few bucks. I am hoping Eagle R &D will replace it.

Stan

JEFF TIPTON

06-20-2009, 04:49 AM

Bummer. But now is better than later.

StanFoster

06-20-2009, 02:30 PM

Even though I tore my helicopter all apart ...progress was made.

Yesterday I took all the control rods to the swashplate off..removed the two lower fuel tanks...and dropped the transmission...Today I took the cabin off ...which is nothing but a 5 minute job...then the top tank came out of its frame work.

I studied the welds that were bearing against the plastic...and though they were smooth....they were bulgy. So..I filed them down.....and even discovered some welds that I also filed down that were touching the lower tanks.

I still think the tank just happened to have a bad casting....that along with that one weld...stressed it too much.

I really am glad I know about it now....as I did a lot of stress relieving on the other welds. It HAS to be much better now. The special plastic for these tanks have an elongation factor of 700%...which means they are supposed to be able to stretch 7 times their width before failure. I still think I just had an unfortunate casting which happened to be right at that weld. This plastic is very stretchy.

The first pictures are the untouched welds...then after I filed them.

The finger is pointing to the hairline split in the tank which I can make out in the picture.

While I was tearing my machine down...I went ahead and took out the instrument panel and have it at my painters. He is going to be painting my tail rotor driveshaft....instrument panels... door hinge brackets...and my pitot tube all burgundy at one spray session.

Stan

All_In

06-24-2009, 08:32 AM

I was on a drive about for the last week and missed your last two posts.

It's really looking professionally built Stan!!!

You kept the water in there for so long, I was thinking it was long enough when you discovered the leak. You are a very wise man! Great lesson for me to learn, thanks.

StanFoster

06-24-2009, 05:19 PM

I shipped my top fuel tank to Eagle R#D yesterday. I am getting it replaced with a new tank. They want to cut it open and see why it split. This is rare, and I am thankful that it started leaking now...when it wasnt that big of a deal to fix it.

Stan

Dirtydog

06-24-2009, 05:34 PM

StanFoster :
:suspicious:Now I can relate to that Stan...... Just not any good!:suspicious:

birdy

06-25-2009, 12:42 AM

Bloodyell, i could never fly sumthn like this Stan, id always have me hand on the rong stick. :(

StanFoster

06-25-2009, 02:12 AM

Birdy- Anyone here knows you can do more with a gyro than most can with a chopper. You dont need them extra controls! When I get this thing flying, I am going to muster me up some moos. Or maybe it will be fluster up some moos? ha Take care down there. Stan

birdy

06-25-2009, 07:22 PM

You dont need them extra controls!
Wasnt refern to the controls Stan.
If i sat in sumthn as spiffy as your machine, well, id have to grab the grissle. ;)

Graeme Monro

06-25-2009, 09:35 PM

Takes a while for these foreigner's to catch on doesn't it Birdy.

Graeme.

StanFoster

06-26-2009, 02:33 AM

Graeme- I am not retarded......just s-l-o-w. ha.... Stan

StanFoster

06-26-2009, 06:13 PM

I picked up my tail rotor driveshaft sections, instrument panels, pitot tube and some door hinges from my painter today.

I am looking forward to see how the black instruments will look installed in the burgundy panel. The recessed area with the black circles are the velcro circles that secure the GPS behind the panel. I taped over the circles in case the painter didnt.

I received word that a new fuel tank is enroute with no charge. They are going to demo my tank and analyze why it failed. They havent seen it yet..but I told them if it looked like I beat it into the frame with a sledge hammer,...then send me the bill for it!

Stan

StanFoster

06-27-2009, 11:34 AM

I put the dash panel back in. The last two shots are a bracket I made to hold the rotor speed sensor. This will be within 1/32 to 1/16 inch away from the rotor drive shaft.

Once my new tank arrives...I can start putting this chopper back together and get caught up again. My 3rd shipment is about to leave port.

Stan

utahgyrocop

06-27-2009, 12:01 PM

Stan,

Looking great!

Just wondering, other than a radio on one of the holes, what is going into the other three?

Thanks for sharing.

Stay safe!

StanFoster

06-27-2009, 12:13 PM

Doug- Thanks...The two holes below the GPS are for my radio and transponder.

There still are some gauges coming with the turbine....oil temp, oil pressure...

I have a hole cut for a fuel flow gauge should I want one....or a HDI. I decided to cut them out....and if I dont want to buy a transponder say...I will plug a clock in there. There will be no open holes when I am done.

Same as for my 10 switches and 10 breakers. I will have one or two switches left over for future additions....or changes. If I am not using all the circuits...there will still be a switch in the hole waiting for future additions. I may say want to wire interior lighting...or have panel lights should I decide to want to illuminate my panel better.

Stan

animal

06-27-2009, 12:18 PM

Stan. I am disappointed that does not meet your high standards of construction.

I think you should take it out and mail it to N.C. lol

no that really does look great. so how long till they ship that Turbine?

StanFoster

06-27-2009, 12:33 PM

Tim- I have no idea on the turbine. They are working on them now. I have gotten used to just dealing with whatever parts I have. I am just in piddle mode most of the time...trying to do a good job. Now...if the whole Helicycle was sitting there in the corner in a stack of boxes....I wouldnt be typing on the computer right now.

When I build my SparrowHawk...I averaged right at 100 hours per month. I am just pacing myself at a small fraction of that rate. Its not necessary to go at this project like I am killing snakes......chip...chip...chipping away.:yo:

Stan

animal

06-27-2009, 12:42 PM

Well keep up the good fight Stan, it will be well worth it when done.

I wish my workmanship was half as good as yours.

StanFoster

06-29-2009, 02:37 PM

I reserve a few days each month to get out of the shop and see what holes are being dug for new homes. The bigger the hole....the bigger the home...:)

Anyway...I used my SparrowHawk and its GPS for a very handy search for stairway prospect flights. I would go make a cross country to a large metropolitan area...fly the perimeter mainly around the lakes...woods...and rivers....and you would not believe what you find that driiving for days would not. I would then waypoint the location of the holes....and return soon with the GPS quickly taken out of the dash...and put into my truck. I would just meander around and find the holes...then almost always theres a sign there to get the contractors name.

Today...I stole the GPS out of the Helicycle...put my landmap chip in it and used it to drive to different contractors after I found the holes...called them up.,.and got their addresses.

Heres a few pics going down the road with it stuck to my instrument panel.

Once the Helicycle gets its 40 hours flown off...it will be put to some stair hunting missions.

Stan

StanFoster

07-07-2009, 06:41 PM

Just a little update. I recieved my replacement fuel tank from Eagle R&D,,no charge...and they cut my old one open to see why it had a split in it.

They really found no reason...the tank was indeed full thickness where it split. This seems to be an oddity. Anyway, I did not want to have a "repaired" tank in a new chopper, they listened and granted my wish with no problems. While my old tank was in transit to Idaho, I asked that they ship me a new one....and then if they decide I had put my tank in with a sledgehammer, to just send me the bill for the new tank. They decided I had not been rough with it...but the disappointing thing about this all is that nothing was learned about why a split developed in it. It was over a frame weld...but they said even with that fact....the tank has a 700% elasticity factor to it....so we are all puzzled.

I promise I wont put the new tank in with a sledgehammer again! :yo::tape:

I am going to be putting this all together again soon when I get caught up. It will be nice to have it back together again.

My 3rd shipment is crated and ready for transit. This will be the swashplate, and that awesome work of art they do ....the rotorhead.

My blades will be coming in a few weeks.....so I will be busy again.

I asked about when I might be expecting my Solar T62 turbine.....and was told in November or December. Thats fine with me....just so I have it this year. They say there is only about 30 hours of work to put the turbine in....so even if thats way conservative...I have the winter to look forward to finishing this up. I can easily deal with that.

They have logistical problems procuring certain special bearings that they have outsourced...and are at their mercy....and of course we Helicycle buyers just have to deal with it.

This has made my build non hectic....and I really have been enjoying it.

One major point that keeps me enjoying this build......most builders of extensive aircraft kits spend more hours building their aircraft than they spend hours actually flying it. That point holds true with me. My SparrowHawk took 503 hours to build...and I did fly it 240 hours.

I would guess that my Helicycle will take close to 600 hours to build more or less.....and that will be a lot of flying for me to surpass. I made a promise to my wife that I wont be building any more aircraft kits.

I worded that promise carefully......someday a long time down the road...I would like to build a single seat gyro of my own design....so this would not be a kit in my mind.:yo:

Even though I would love to be flying.....I have been very content with this build....actually loving the whole process.....even the wait on shipments.

Stan

PR_Arecibo_DC

07-07-2009, 08:04 PM

Stan,
Cant wait to see you flying your heli... Just want to see your expresion in your face when you crank that turbine for the first time...

Anyway... about your tank...
When I was in the Army working with the M1 Abrahams Tank, we had a leak in one of the rear fuel tank... After General Dynamics personnel review the tank the only conclusion was that when the tank was build the material viscosity was a bit ticker than normal and it might be create a small air bubble in the molding process and thats where the little tiny split was found... This might be the case with yours or might not...

Oh...Stan make sure you take picture of Santa when he deliver your T62 Engine... Dont forge tthe cookies and intead of milk leave him a glass of Kerosene... he might deliver the present quicker....lol

Have fun Stan

Jose

All_In

07-08-2009, 07:21 AM

If others aren't having any problems with it, chances are it's a one time defect.
But your long term water testing will help disclose any recurring problems, good job.

However I'd add to your pre-flight check list, running my finger over each friction point with the tank and frame meeting, checking for leaks?

Great attitude Stan, you got me beat with the whole waiting for shipments thing....

StanFoster

07-08-2009, 03:57 PM

I put the new top tank in...and this let me get the cabin back on. It feels like I am progressing again. Here are the first shots of the new panel inside the cabin.

Tomorrow I have some time scheduled to reinstall the transmission...and the collective/cyclic controls.

Then once my new o-rings arrive...I will re-install the lower fuel tanks.

Stan

StanFoster

07-09-2009, 02:41 PM

New progress today. I reinstalled the transmission....then assembled my painted tail rotor driveshaft.

You can see the 1/8 pin punches that align the bearing holders. This driveshaft can be taken out of the helicopter in ten minutes...then placed back in and by using those punches..the alignment is exactly repeatable.

If you look closely at the bolts going through the burgundy driveshaft pipes...I reversed the head/nut relationship across the bearings...as I figure this would offset any imbalance of having the nuts at the same place. This way if there is any difference in weight...which there has to be a little..then its basically balanced out.

I did all but restring my fishing line to just verify that it is running true the full length....I will do that soon just to satisfy myself that all is to specs.

The lower fuel tanks are waiting on the new florocarbon o-rings...and it will soon be back to where I had it...plus now the instrument panel and the painted tail rotor shaft are in.

I just wanted to get all this buttoned back up before I go to Homers in a few weeks.

Stan

StanFoster

07-10-2009, 06:11 PM

I made a bracket to hold my hall effect sensor for the rotor tach. It is riveted to the transmission vertical brace. That brace really isnt vertical...as it angles just a tad. This angle is reflected in the bracket I made that is riveted to the brace. You can see in the first picture it is not quite square...but the hall effect sensor is square to the rotorshaft magnetic buttons because of this angle bent into the bracket.

My 3rd shipment is in transit from Idaho as I type. I was told my rotorblades are coming inn 2 weeks. I will have lots to do just making and bonding the doubler plates to the rootends of these blades. Lots of fun stuff coming up.

Stan

animal

07-10-2009, 06:15 PM

Looking good Stan.

dabkb2

07-10-2009, 06:20 PM

Looks like you are having fun Stan, as usual.

PR_Arecibo_DC

07-10-2009, 07:18 PM

Hey Stan,
How comfi is your heli seat?

All_In

07-12-2009, 06:41 AM

Yaw Mon!

We be build'n!!!

I love to watch you work.

StanFoster

07-12-2009, 06:52 AM

My 3rd shipment is enroute.,..and I decided to get my hanger floor epoxy coated. I scrubbed and swept it out...then etched the floor with muriatic acid. I never sealed the concrete as I knew I was going to epoxy it this summer. Anyway...the muriatic acid was rinsed twice...and now I will mix the epoxy tomorrow and roll it on. I am going to speckle the light gray floor with colored flakes.... It will be nice to have a floor that is smooth and not a producer of dust everytime I sweep.

Jose-....The seat is very comfortable...the legroom and shoulder room are very good.

Stan

All_In

07-12-2009, 07:14 AM

Good news on the 3rd shipment.

Stan is a great lesson on success.

Notice how he's always working, building, doing.

It's more about the amount of time you spend, just doing it, than anything else.
That and knowing you can't fail, until you give up and quit.

Gerrydobro

07-12-2009, 02:31 PM

Nice build Stan! looks real clean and nice!
Gerry

Kandace

07-12-2009, 06:41 PM

WooHoo! 3rd shipment coming more build progress! I don't know who is more excited Stan or ME!

Kandace

StanFoster

07-13-2009, 02:27 PM

The floor is epoxied....now I cant work out there for a few days...the fumes are awful.

Stan

StanFoster

07-13-2009, 02:37 PM

My rotorhead and swashplate arrived today. I now understand other Helicycle owners comments about even though we have to wait a long time for our shipments....when they come...they are first class.

This rotorhead is a work of art to see it in person. Beautiful finish on it..radiused corners....all preset and not to touch.

The rotorblades are coming in two weeks and I can just imagine what they will look like.

Stan

animal

07-13-2009, 02:48 PM

Wow that looks nice Stan. how hard was that to do? and was it very costly?

one of these days I need to clean my shop out and seal or paint the Concrete in it.

animal

07-13-2009, 02:51 PM

Stan,that Rotor head is sweet looking, whats it pivot on? it looks like a steel insert on the inside of the teeter blocks.

All_In

07-13-2009, 03:22 PM

SWEET!

They do good work, it getting exciting.

Your new floor looks great too!

StanFoster

07-16-2009, 04:53 PM

I can just now reenter my hanger....that epoxy smell was terrible the first 3 days. My rotorhub an swashplate are awaiting to be installed. I have a little time next week to get back on it.

The rotorblades will be arriving early August....so after Mentone I will get back into my groove of hitting this project a little each day or so..

Stan

All_In

07-16-2009, 04:55 PM

Like all you do, the floor looks great!!!

What a hanger!!!

Dirtydog

07-16-2009, 05:28 PM

NAAAAA need a little more wax there Stan on that floor........:boink:
Coming along, closer....... Looks great too! I like having the grease fittings on the R/H. I wish mine had them.

StanFoster

07-16-2009, 05:36 PM

Dirtydog- I about busted my butt on that floor. I was watching a centipede that had come in under the door. His legs were spinning out as he traveled the 34 foot depth. I estimated that he was spinning about 90% of the way...so that was like going 300 feet down a football field for him. :D

I actually am not done with the floor. One more finish coat ....then I will need suction cups on my shoes to pull the chopper out.

I have never had a floor that you can move around on your back like you have a creeper under you! I decided all along if I was going to the expense of having that Helicycle...it was going to have decent home.

Stan

animal

07-16-2009, 05:37 PM

Wow Stan that does look nice. what kind of coating is that and was it hard to put down?

also what type blades do they use? composite or metal?

of you look close you can see the Rotorway heritage in the swashplate casting.

that is a nicely designed machine.

StanFoster

07-16-2009, 05:42 PM

Tim- That is a Rust-Oleum product epoxy kit. Its not the hardware store type...but the industrial coating.

The floor prep is the most important. Clean it with water....then muriatic acid is applied to etch the concrete. This eats that fine dust off the concrete that you MUST get rid of. After its dry...if you have dust on your fingertip...do it again.

Its just a rolled on product....the decorative chips were applied....then I put an epoxy clear coat over the top when the epoxy was cured.

Stan

HobbyCAD

07-17-2009, 12:44 AM

Stan,

Do you think the decorative speckles you put on the grey epoxy was a good idea? What if you drop a small part, like a grubscrew or small nut, will you be able to see it against the speckle background? I was spoiled rotten, when staying in the Middle East, I had full marble flooring in my workshop!! It has the same decorative look as your paint speckels. I'd have to get down on the floor, with my eyes as close as possible to the ground, and try and pick out the object raised slightly above the floor. That's usually the little thing I dropped.

Regarding your main transmission pictures in post #473, how is the main transmission lubrication pump driven, is it somehow driven off the input pinion? I like the forced lubrication of all the main bearings in the unit.

Regards,

Francois

StanFoster

07-17-2009, 02:30 AM

Francois- I dont think It will be much of a problem finding a small washer or whatever is dropped on the floor. If you get down at a low angle, the decorative chips disappear undr the sheen of the floor. I can also slowly sweep the floor with my fingers and feel anything on the surface it is so smooth. But, you have a point that initially when looking from higher up, a small part could disappear in the monetany of all those chips! Like anything in life, it was a tradeoff in looks. I decided before I put the chips on the fresh epoxy, that a floor ok one color would always be showing dirt spots, etc. and I just wanted to give it some life. Stan

Mark E

07-17-2009, 10:44 AM

Stan - love following this thread - beautiful work .... (helicycle, helicycle home, and stairs!)

....but PLEASE fix the white balance on that camera! ... that warmth spoils the colour (for me anyway)

StanFoster

07-17-2009, 12:16 PM

Grimwat- I know you have been disturbed by something in my pictures before, but I cant for the life of me know what you are talking about, nor do I see anything wrong. I know my pictures arent high quality like Eds and Tim O'Connors, but I dont see anything wrong with them. ??????? I just set it and forget it! Stan

PR_Arecibo_DC

07-17-2009, 02:00 PM

Stan,
Awesome job with your new Garage/Hangar.... Floors are nice... You should include it in your stairs business..."We do you stairs and epoxy your garage"...

Stan, as a rough guess... how much the rotorhead and swashplate weight?... I know is the picture but they look really heavy... just a curiosity...

Oh, before I forget... Stan, I took the liberty of showing your build pictures to a few of the UH-60 pilots here and their crew chief... and they are in love with you Helicycle... Except one of the Crew Chief that likes Animal Falcon, he talking about buying the kit and put it togeather here in the shop... It will never happen...all this officers will stop him on a heart beat...... so guys sorry but I show all your pictures to some good aviators over here in Iraq... Please dont sue me...lol...

Jose

Mark E

07-17-2009, 06:22 PM

Sorry Stan! ... didn't think you'd got that note, otherwise I would not have posted that again.. They're your pics, and you're happy. so I'll just keep enjoying the build!

StanFoster

07-17-2009, 06:26 PM

grim- no need to be sorry... If I knew what is wrong with my pictures...and what to do to fix them...I am all ears. But...you will have to let me know when they improve...cause I probably wont be able to tell!:lol:

Stan

Resasi

07-17-2009, 06:28 PM

Immaculate work Stan. :yo:

The suspense of just having to wait for those parts must be something else. It is certainly keeping us all on the edge of our seats.

StanFoster

07-17-2009, 06:44 PM

Resasi- Sure...I would love to have the shipments much closer together to speed my build....but I really am enjoying savoring this project. In my down time...I was able to get my chopper channel all opened up and seeded down.....my hanger room added on.....and this last waiting period I decided to get that floor epoxied. The hardest part of this project is listening to my local friends who by the way never build anything on their own...stop by and get their shorts all twisted in a knot commenting when I am going to get this thing done. I have told them I am getting impatient with their impatience!

I am not building on their timetable and I think they may be getting a lesson in patience. I cant explain the sense of accomplishment I feel when I go out in that hanger. I have a lot of good build memories yet to go...and I dont want to rush it.

Stan

RotoPlane

07-17-2009, 07:13 PM

I was wondering Stan….does that swashplate use a uni-ball for its gimbal and if so, is it plastic? I've been hunting for one for so long……sniff.

StanFoster

07-18-2009, 03:36 AM

Ed- It just looks like a gimbal head with pivots at each 90 degrees. There is no ball in it. It is very well designed and built....and that rotorhead is something else. I feel like putting it on the mantle.

When it arrived..and after my jaw closed shut....I called Caroline Schramm. I told her that my rotorhead arrived....and I commented ... "After unpacking and looking at that rotorhead....it is a piece of...........art! " As I purposely drug out my last word...I could almost hear Caroline gasp....

Blake at Eagle R & D is a perfectionist. His stuff is worth waiting for. The only critisism I have ever had with him is that he will unintentionally milk the dates to ship stuff back a little each time you talk to him. He is sincere....he just probably is walking a fine line trying to keep perfection and his schedule together. One fights the other though...and I have no complaints waiting for a superior product instead of having whatever right now. When I am done building this helicopter....I will have a unique advantage that many helicopter pilots dont have..daily access to my chopper so as I can do the extra maintenance and checkovers a helicopter requires! If it was parked at the airport like my SparrowHawk was, it would be under less than ideal conditions for owning and maintaining one.

Stan

StanFoster

07-18-2009, 03:44 AM

Rotoplane- Here are a couple shots of the swashplate. I dont recall if I posted these before.

Stan

StanFoster

07-18-2009, 03:49 AM

Francois- I missed one of your questions. The pump is internally geared inside the transmission, and like you commented, the oil is externally routed and forced fed to the bearings. There will be an oil temp and oil pressure gauge in the panel...as well as a chip detector. B.J. did a nice job designing stuff...

More build pictures soon. I have to get caught up on stuff called....making a living...and getting my helicopter rating. Next I will be re-installing my lower fuel tanks....final plumbing for them, then the swashplate is next. The rotorblades should be here in two weeks....and that will be very interesting work that I am looking forward to. I have to cut out the doubler plates, a stack of 3 that ease the stresses out at the root of the rotorblades. These have to have to be cut out to a serpentine pattern...then curved to match the airfoil shape. The mating surfaces have to be thoroughly, and meticulously cleaned,....then bonded together. After this...the rotorblades are shipped back to the factory...where they will final balance them. When my blades come...this will be top priority for me...as they do these in groups....and each group can take quite awhile.

Stan

RotoPlane

07-18-2009, 05:40 AM

Thank you Stan for the pictures. The swashplate appeared so small that thought it used the uni-ball, but I can see the gimbal now.

Arnie Madsen

07-18-2009, 08:50 PM

Stan.

We men do not fuss over jewelry like the girls do. A sparkling diamond set in a bit of gold will keep her happy for at least a year. I have never completely understood exactly how that works. I only know it works.

But when I saw the pictures of your rotor hub , I thought I was in a jewelry store for men. Diamonds in the sky with a helicopter attached.

Arnie

dennisu

07-18-2009, 09:15 PM

Animal

Stan,that Rotor head is sweet looking, whats it pivot on? it looks like a steel insert on the inside of the teeter blocks.

I don't think Stan saw your question so here is the answer. The head teeters on a set of heavy duty Timkin bearings greased by the zerk fittings on the upper part of the teeter block. What you are seeing in the picture is the foil tape over the bearing to keep it clean.

StanFoster

07-19-2009, 03:01 AM

Dennis- Thanks for catching that question from Tim that I missed. Sorry Tim!

Arnie- I know what you mean! I dont know if I want to put that rotorhead on a ring...but it would look nice on my mantle. I kind of doubt the wife would appreciate what I would have to move though to put it there.

Stan

All_In

07-19-2009, 08:25 AM

Women are funny that way?

Stan: "But it looks so good to me sweetheart, what's wrong with it?"

StanFoster

07-19-2009, 09:02 AM

My wife Barbara saw my hanger floor...."Can we do something like that to our garage floor?" she so sweatly asked the other day. I told her very sternly...but with just enough authority..."that yes we can do it to our garage floor...but no we are not!" You just have to show these women sometimes who really is the boss!

I just came in from epoxing our garage floor ...the epoxy fumes out there are strong....:painkiller:

Stan

All_In

07-19-2009, 09:05 AM

That's what I thought!!

After reading the first line, I was going to ask.

So when are you going to do it?

I see it's done!!!

I'm still laughing......

animal

07-19-2009, 09:20 AM

yep,the women do have a away of getting what they want.

hows that saying go.. when momma not happy..no one is happy.

StanFoster

07-19-2009, 03:40 PM

Tim- Mamas happy now...she has a new epoxied garage floor. Like you said...when mamas happy, I am happy!:yo:

Stan

utahgyrocop

07-19-2009, 08:41 PM

The other half of the phrase is when Mama's not happy nobody's happy. Congrats Stan the project and the hanger floor are awesome.

Stay safe.

StanFoster

07-20-2009, 05:15 PM

Heath- Thanks. I noticed the other day that one of my oil lines on my transmission had a small crease in it. It "probably" was ok...but that isnt good enough...so I called the factory and talked to Blake about maybe having him make me one sometime. That was just last Thurday....today it was in my mailbox.

So, I had always heard that even though the shipments are a long wait...any special request gets the front burner.

Stan

All_In

07-21-2009, 12:28 PM

OK you told me you put the tank back in... where are the pictures?????

Also Stan, you got some strange (sick) friends that love your helicycle way tooooooooooooooo much.

To bad you can't share his comments in public, (very sick) but I'm still laughing.....

I think he is in love!!!

StanFoster

07-21-2009, 03:33 PM

John- yea...I would be banned if I typed what my friend said about my Helicycle.

I now have my fuel tanks all back in after my top tank was replaced. Even though this was a lot of work taking all them out...dropping the transmission...controls...etc.....it would have been a lot more work later after the cabin was all buttoned up ...windshield bolted in....rotorhead on...swashplate on...rotorblades on....God..I dont even want to think about it.

My goal was to get this chopper back to where it was before I go to Homer Bells huge 25th anniversary fly-in this weekend.

Next week I will resume work on getting the swashplate hooked up to the three control rods you can see in the one picture...and putting my rotorhead on.

My rotor blades will be coming soon....and the build will continue.

I could have been working on my wiring....but I hated to see fuel tanks laying around....and other stuff that used to be part of this chopper. Now its back to its heaviest weight...and getting heavier!

Stan

All_In

07-21-2009, 03:36 PM

Oh man, that does really look SWEET!!! As my kids have got me saying too.

StanFoster

07-23-2009, 05:10 PM

Today was when I tested my fuel tanks. I filled them all up with water...and anxiously awaited to see no dripping...or so much as a drop. After sitting all day...there wasnt one drop ....so I now feel ready to go on with my swashplate and rotorhead assembly. My rotorblades are coming soon....and things are going to be busy again. :yo:

My 17 month old grandson Colton stopped by for a visit to the hanger...and I took these pictures of him. I have completely ruined that young lad. He holds his little toy helicopters above his head...and makes helicopter noises. It is so cute to watch.

Heres some pictures of him operating some switches. He goes for anything with a button or a switch on it.

The one picture where Colton is headed for the tail rotor....is exactly what he was doing. I stopped him just in time as he always spins his rotors and tail rotors on his toy choppers. That little fart is something else...but whose grandchild isnt? I am working on ruining my grandaughter as well...but she isnt walking yet.......give me time....more time.....I am very patient....:yo:

Stan

All_In

07-23-2009, 05:14 PM

Oh that is the cuties thing I've seen in a very long time!!!!

He's going to be a helicopter pilot, you wait and see. You just planted the seed so young and you'll keep watering it each time he see you fly.

PS:
Stan I can't find your Air Commander Thread? How about a bump for me.

StanFoster

07-29-2009, 01:16 PM

My rotorblades will arrive next week. I will then have to cut out 16 doubler plates as can be seen at the root of this rotor blade I posted a picture of. These spread out the loads at the hubend. They have to be cut out and then shaped to the airfoil section. The aluminum has to be thoroughly cleaned and prepped for bonding. Once I have these blades bonded...tip weights installed and various other details...I will ship these back to the factory for balancing and machining.

They do these in batches...and it can be months between batches...so I will hit it hard and get er done....

Stan

animal

07-29-2009, 07:14 PM

Wow, thats alot of cutting but I am sure you will make it will look great.

StanFoster

07-30-2009, 02:03 AM

I am starting back again on my Helicycle today. My rotorblades will be enroute, so I want my swashplate installed, rigged, and completed before my blades arrive. Pictures tonight. Stan

StanFoster

07-30-2009, 01:34 PM

I installed the swashplate today. First order of business was leveling the rotor driveshaft both ways. I had to shim the left skid a tad over an inch to level it. I measured the base across my transport wheels...and it was 58.5 inches. I divided the 1.0625 inches I had to shim it by this 58.5 inches...took the tangent of that and and this computes to a 1.04 degree tilt to the left. My inclination gauge only reads to within quarter degree, now I know exactly.

The swashplates machining was superb...its fit down the rotor driveshaft was precise. The heim control rod ends fit with 0 slop. They are very fussy on this stuff. The swashplate has timken bearings in it and was a pleasure to install. I rigged it so it has 6 degrees fore and aft...and rigged the swashplate level with 3 degrees right input to the cyclic.

The last pictures are my laser beam aligning the back of the stabilzer bracket. Its supposed to be at the dead rear...so I just split the rotorshaft down the center with the laser beam...and made sure the plane of the laser light was dead center on the tail. I then clamped the stabilizer bracket to the hood bracket...drilled it for its bolts....then painted it. Its now on permanently.
Next will be the rotorhead .....

I have more pictures to post later....time to play with my grandson.

Vance

07-30-2009, 01:38 PM

Nicely done Stan!

Thank you for the inspiration, Vance

animal

07-30-2009, 02:56 PM

Looking good Stan, getting closer.

I bet you can't wait to get your blades mounted.

StanFoster

07-30-2009, 05:11 PM

More pictures of the swashplate. It starting to feel like a helicopter.

You can see full left and right cyclic. Everything is set to specs... I am experiencing what other Helicycle pilots have been telling me...this chopper is very easy to rig....and the maintenance and adjustments are very minimal.

Stan

Resasi

07-30-2009, 11:53 PM

Stan such a real pleasure to see the care and loving attention that is going into this piece of art.

Know what you mean about the grandchildren, they are so very special...and... you can hand them right back when they get a little tetchy. My third is on the way. Hoping it might be a boy. Girls are nice but boys can be real fun too.

animal

07-31-2009, 05:08 AM

Stan what are the setting of the swashplate? how much tilt angle does it get?

looking more and more like a helicopter now for sure.

StanFoster

07-31-2009, 06:10 AM

Tim- The swashplate is now set to specs....6 degrees forward tilt, and 6 degrees rearward tilt. 7 degrees left tilt, and 6 degrees right tilt. The cyclic stick itself moves roughly 45 degrees laterally and for/aft to move the swashplate 12-13 degrees.......that is why the Helicycle is not sensitive to small stick movements. It has a nice large movement to adjust the rotor. Also the collective has progressive geometry designed into it. At take off... the collective has to move quite a bit at this stage to change the rotorblade pitch, this gives you more finesse for better precise pitch changes needed at this point. But when you are autorotsting in, and you need to add pitch much faster, the geometry of the collective linkage is such that small movements towards the top third of travel give more pronounced pitch changes. You dont need finesse at this time, but some serious angle changes to the blades. B.J. Schramm has done a wonderful job designing this chopper, and the testimonies I keep hearing from Helicycle pilots makes this build so enjoyable , and looking forward to adding more positive testimony myself as I experience flying one for myself. I have never enjoyed NOT flying as much as I have while building this. Stan

PR_Arecibo_DC

07-31-2009, 09:01 AM

Stan,
nice job...

When the time comes for you to fly it for the first time, do you going to video taped and post it in youtube.com? I bet you that a lot of people including myself here are waiting for that moment anciusly like your self... We have a both way trill here...

Have fun and be safe

Jose

StanFoster

07-31-2009, 11:54 AM

Jose- I will make sure the first flight by Doug Schowchert , and my first flight will be on a movie clip. My first solo in the R22 is on U-tube and I was happy my instructor ran my camera right.

There does seem to be a little interest in this project..:D

I took one blade grip off to show the inner workings of this beast. That shank will contain the elastomerice bearing that they are holding back from me until my checkout. There are a couple of requirements before they hand those bearings over to a customer.

1, They have to have prooif of you at least soloing an R22...with a sign off by a CFI.

2. The machine must be gone over by one of their factory technicians...and then test flown also.

Eagle R & D want to keep us safe.

Stan

Gyropilot007

07-31-2009, 01:07 PM

Stan:

I'm very excited and happy for you. What a tremendous accomplishment. I really can't wait to hear stories of your flying adventures. And your copter looks like a work of art! One day I hope to see it in person.

Bob

PR_Arecibo_DC

07-31-2009, 03:38 PM

Stan,
When you say "and I quote" ,

<QUOTE> The machine must be gone over by one of their factory technicians...and then test flown also. Eagle R & D want to keep us safe. </QUOTE>

-Do they come to your location or you have to take it all the way there?
-Do they do all the Test Fly?

Jose

StanFoster

07-31-2009, 08:07 PM

Jose- Part of the contract of buying a Helicycle is having the factory checkout. It is an intensive 4 day top to bottom going over the machine. Turbine start up, adjusting, main rotor balancing...tail rotor balancing....verifying all the controls are set to specs...all critical stuff safety wired, etc. They come to you to do this. Doug Schwochert will be doing mine...and he will be the first to fly it. Then it will be my turn.

I will have some fresh R22 solo time just prior to this. They all say if you can fly an R22, this is much easier..the controls are quicker to respond. I am looking forward to experiencing this. I will have the turbines first start up, Dougs first flight, and my first flight on video. John Rountree wants to fly out from California and be part of this experience. However....I am going to keep it quiet locally. I dont want a mob of people around.

Stan

StanFoster

08-01-2009, 03:36 AM

Had to laugh at my grandson at the controls.....Barbara is saying....no,,noo

Stan

StanFoster

08-01-2009, 03:56 AM

Bob- Thanks. I cant wait to see you flying your gyro again. I really enjoyed that time you flew down to Urbana to Rudy Frascas fly-in...then followed me back to my airport. You had a beautiful ship....and you will get it back flying. Just hit it at a part at a time...then the steady progress you see will keep the momentum going. We all want to see you back in the air Bob.

Stan

earthbnd misfit

08-01-2009, 05:14 AM

I think the factory won't be coming out to inspect it, but to see how it's done properly.:D

All_In

08-01-2009, 05:19 AM

Very cool, really starting to look like it almost done too!

Love the shots with your grandson flying!!

PR_Arecibo_DC

08-01-2009, 09:09 AM

Stan,
I had no idea about the the company actually coming to you and do all the safety checks... I am definetly impress...

Stan, would be better if you get some stick time on a ship with a normal cyclic (Stick) before flying your Helicycle???... I am still find the R-22/44 T-Bar cyclic anoying... would be any difference for you?

So, when is going to be the first "Stan's Fly-in" ?

Jose

StanFoster

08-01-2009, 01:18 PM

Jose- The factory is really carrying on B.J. strict policy of having a factory checkout...and insuring that the kitbuilder can fly an R22. Everyone tells me that if you can fly an R22....the Helicycle is similar..but much less sensitive...

I cant imagine having any problem with a regular stick compared to that silly R22 T-bar. That R22 would be perfect if it had a center cyclic.

StanFoster

08-01-2009, 01:25 PM

I finished painting my pitch horns on the rotorhead..and my swashplate.

I am using this highly recommened oil for the main transmission and tailrotor gearbox. The tailprotor gearbox is now full...and you can see the sight gauge in the last picture.

Stan

animal

08-01-2009, 04:03 PM

Stan, what kind of paint ya using on the parts? it looks good.

StanFoster

08-01-2009, 06:37 PM

Tim- I have had good luck with gloss white Krylon paint. if I scratch it, I can fix it. Stan

animal

08-01-2009, 06:44 PM

Tim- I have had good luck with gloss white Krylon paint. if I scratch it, I can fix it. Stan
Well it looks really good. the detail work on your chopper is great. I still say you will have a show winner when you get it done.

I just came in from working on the Commuter,needless to say it don't look anything as good as your bird.

StanFoster

08-02-2009, 03:36 AM

Tim- Thanks for the comment. Dont forget that just like you are doing....I have stair stepped up to each project....no pun.:p This Helicycle is my 9th aircraft..the first was an ultralight...the others were gyros. I used each one to help buy the next one. This will be my last kit I will build....I plan on flying this for a LONG time. I have no more plans of purchasing any other rotorcraft....the only exception being building some kind of single place gyro of my own design....for the challenge of it and to give my Helicycle some company in that hanger. ...composite construction, maybe way down the road several years.

Hey...I sure would like to follow what you are doing on your Commuter. I know you said upfront you do not intend to fly this one..but rather use it as a stepping stone to your Commuter 11 dream. You mentioned your project not being as nice.... I think anyones project is just as nice to them, its what they are working on with their available skills and budget. Thats what makes it nice to me.

I am wanting to see what you are doing to make your helicopter nicer....pictures .. start a thread,,,,PLEASE!!!

Stan

StanFoster

08-03-2009, 02:01 PM

I installed the painted swashplate this afternoon...the locking rings that are hidden under the boot...and the accordian boot.

The last two pictures show full down and full up collective.

The rotorhead will be temporarily installed next...the pitch links will be installed. I am pacing my work on this according to parts arriving.

My rotorblades are on the truck today and headed to Illinois from Idaho. I will be ready for them...getting their doublers cutout and bonded to the blades. The blades will then be shipped back to Idaho for final balancing.

That process will take a few months as they wait until so many are ready,,then they do a batch. There are blades coming from kits sold over 4 years ago....not just my group.

Stan

Resasi

08-03-2009, 02:51 PM

Stan, I am thinking of a fine wine slowly coming to maturation.

StanFoster

08-03-2009, 05:22 PM

Resasi- Thanks..... I am looking forward to the fine whine of the turbine!

Stan

Resasi

08-04-2009, 01:58 AM

Stan, difference between pilot and turbine?.....When turbine shuts down it quits whining.

PR_Arecibo_DC

08-04-2009, 10:18 AM

Resasi,
Good sence of humor I might say... I like your joke...I think I will stole your joke and use it at work with our pilots... Hope you dont mind...

Jose

All_In

08-04-2009, 11:45 AM

You guys crack me up!
I heard if a turbine stops whining in the air, the pilot starts whining?

StanFoster

08-04-2009, 04:31 PM

I tried out the temporary transport wheels on my rock driveway today. Not good...as expected. These are definately not for "off roading":twitch:

My permanent wheels will be much taller and fatter...plus I will have a helipad that connects to my hanger door.

The last two pictures are from a request to see the bottom side of the swashplate. You can see the cone shaped interior it has to clear the mast as it pivots. These pictures show max for and aft deflection of 6 degrees each way.

Later I will add a link to a You-tube video of my swashplate being articulated full for/aft, left/right...and full up/down on the collective.

Stan

StanFoster

08-04-2009, 06:33 PM

There was a lot of good discussion about the delta hinge on a tailrotor.....so I made this short video clip. If you look closely, you can see the degree change in my inclination gauge...and you can see the pitch being rolled out of the tailrotor blade as it flaps.

http://www.youtube.com/watch?v=8NlIs_fl87k

Stan

Arnie Madsen

08-04-2009, 07:20 PM

I tried out the temporary transport wheels on my rock driveway today. Stan

It must be a great feeling to roll out your helicopter and take a picture of it outside the hangar. It has been a lot of months and a lot of good planning to get to this point. Well done Stan. It sure looks good.

Rotor blades and swash plates have always been my favorite subjects. Thanks for the close-up pictures of the swash plate. This is the heart of your machine and I think BJ Schramm got it close to perfect.

I have had a glimpse of what it takes to manufacture the blade root doublers and look forward to how you do it. To cut , and bend , and form , and clean , and properly bond these components to the blades is very precise.

I can't think of anyone more qualified than you. I am talking about the fundementals of bonding components together that are not always straight and flat. Should be interesting.

Thanks again
Arnie

StanFoster

08-05-2009, 10:40 AM

Arnie- First of all, thanks for your comments. Such comments coming from someone like you and several others here gives me a warm feeling. The blade root doublers will be an interesting project. Not only is it so important to have them formed to mirror the airfoil shape, the surface prep and clamping techniques have to right for a proper bond. These of course spread the load as evenly as possible at the root. I have seen examples of this that are flawless, and I have seen one that was uneven in curvature. I know from experience with laminating wood. that a low angle light will reveal and amplify errors. With shiny aluminum...it will be very hard NOT to see any uneven curves, or slight indentations where a gorilla was subbed out to run the clamps! I am green at bonding curved aluminum....but am following my instincts and asking ones that were successful. I do have a good critical eye, and will be more anal about this next step than anything so far. I will post many pictures of this process. Most of the guys are having these doublers water jet cutout for them, but I want the experience of doing that. I most definately will cut each these all in a stack at once so they will all be the same shape, same edge finish, and same weight. None of this cut them one at a time. Stay tuned.... I will be back! Stan

StanFoster

08-06-2009, 07:02 PM

Arnie Madsen

08-06-2009, 10:07 PM

My wife called me at Mentone with the good news that my Helicycle rotorblades arrived! I would not let her sign fo them as I want to personally unpack them and examine the blades while the truck driver waits. I never will forget the surprise I received when I unpacked my Sportcopter blades for my SparrowHawk. The box they were shipped in had no marks of any kind on it, so I didnt check them till much later. I opened them up and they were meticulously packed in high density foam. My jaw about hit the floor when I noticed a crease about 6 inckes long about 2 feet from the end of the blade. I had no success getting anyone to cover this, simply because I could not prove I did not do it. Had I opened them when they were delivered I would have had no problem as I simply would have flatly rejected them. I learned a big lesson not to assume there is no damage to a product inside an undamaged container. Anyway, these blades will just have to wait till Monday for me to inspect them before I sign for them. Stan

This is an interesting comment and very educational to the homebuilder. Tradesmen like you Stan, who have always delivered the quality product your customer requested expect everyone else works the same way.

Especially when it comes to aviation products. There is a built in trust and expectation when we order and receive high priced aviation parts.

It shakes the core of our trust when we homebuilders have to point out a defect in what we assumed was a tested , proven, and safe part for our aircraft.

With these assumptions we are quick to sign the delivery receipt. The last thing we expect is that we should be the ones to inspect the airworthiness of the newly purchased components.

This is a hard lesson to learn. Most people are honest. We just have to examine everything to make sure. Our lives depend on it. Just one more thing the homebuilder has to consider. Very educational Stan. Thanks.

StanFoster

08-10-2009, 03:59 PM

My rotorblades arrived today. They have been riding on the truck since last Friday as I HAD to see them unpacked before I signed for them. They were perfectly packed in solid foam...also wrapped in paper as well. The skin thickness on these are much heavier than my SparrowHawk rotorblades. These things are beefy.

I will be starting soon on making the doublers for these blades....bonding them on...then shipping them back to Idaho for final balancing. Eagle R & D is really a particular company....I mean how many kitsellers require a factor rep to come and spend 4 days going over my ship, and actually fly it before I do? They are very stringent on quality control....and its keeping me on my toes trying to build a product up to their standards. I will find out on my check out week if I did or not. Doug will also fly my ship...and fine tune the trimming of it...and also get me soloed in it as well.

One more shipment is left....the TURBINE!!!

Here are some pictures of the blades...symetrical airfoil....and the rotorhead going on. You would not believe the tight tolerances getting the stainless steel and delrin discs between the towers of the rotorhead.

You can see in one picture a tapered pin that aligns the inner bearing races with the rotorhead coupling.

Stan