Helicycle Hatchery [Archive] - Page 6

StanFoster

10-28-2009, 02:34 PM

I put the fuel pump on...it was on hold until my gascolator was all plumbed up. I upsized all the fittings to 3/8 feeding the gascolator...then from the gasocolator to the fuel pump. The fuel will exit the pump under pressure into a 1/4 inch line.

I will put a sump cup in the bottom of the gascolator to draw some fuel samples. The elbow fitting to the right side of the gascolator has a shutoff valve that I found at the hardware store. It will make it very handy to shut the fuel off while servicing the gascolator. Little things add up to make it a nice system.

This pump can fail as the Solar T-62 turbine has a mechanical fuel pump.

Stan

animal

10-28-2009, 03:30 PM

Looking good Stan, won't be much longer and you should be getting that Turbine.
Any news on your Blades yet?

Jason O

10-28-2009, 03:48 PM

Stan,

Did you test or have reliable knowlage that if the electric pump fails, it will allow fuel to flow through it at a low enough resistance for the mechanical pump to overcome.

Jason

I put the fuel pump on...it was on hold until my gascolator was all plumbed up. I upsized all the fittings to 3/8 feeding the gascolator...then from the gasocolator to the fuel pump. The fuel will exit the pump under pressure into a 1/4 inch line.

I will put a sump cup in the bottom of the gascolator to draw some fuel samples. The elbow fitting to the right side of the gascolator has a shutoff valve that I found at the hardware store. It will make it very handy to shut the fuel off while servicing the gascolator. Little things add up to make it a nice system.

This pump can fail as the Solar T-62 turbine has a mechanical fuel pump.

Stan

StanFoster

10-28-2009, 04:05 PM

Jason- There are a few guys who shut their fuel pumps off inflight. I am not going to as I think there should be boost pressure to the main pump......but....it will run with this pump shut off. The fuel passes right through the pump if it is shut off. Stan

gyro

10-28-2009, 05:59 PM

Stan, If I might add somthing about the locktite. The motors we used on the first gen miniguns had 4 holes in the back that we used to secure the motor. I put small drops of locktite on the treaded holes before putting in the allen head screws and low and behold some of it got inside and built up a small film aroung the contact area of the brushes completly shuting the motor down.
I test fired each unit before I shipped only to have nearly everygun fail after about 2 weeks. I traced the problem to the motor and sent one back to Pittman for evaluation and the tech discovered my mistake. He told me that even the vapors from locktite can form a film just like super glue. So just a word of caution.....use sparingly!

I realize now that the screw pushed any and all excess locktite inside and your application is different but I dont know about the vapor thing....super glue is obvious,
but I have tasted a sweet ani-freeze tast in my mount after opening locktite so somthing is getting airborn from the tube.

StanFoster

10-29-2009, 05:20 AM

Gyro- I am listening to your words from experience. I ran a test...I took a terminal strip...and bathed it in locktite....and took an ohm reading across it. It still read 0...but that doesnt prove a thing to me. I am listening to what you said about it failing later.

It looks like to me I would be better off slightly altering the threads....jimming them up a little....:wacko:.....and letting that hold. I will just have to experiment like I always do before I do it permanently.

Thanks again for the advice.

Stan

StanFoster

10-29-2009, 05:35 AM

Back on some wiring I am thinking about. I want to eventually install a bullet cam...that I can mount to the nose on the exterior....and inside the cabin. I would also like to have a little station for it right behind the swashplate looking forward. B.J. Schramm did this and the video looked cool as you could see the subtle movements of the swashplate as he flew the rotor to a new plane.

I of course want to control this easily...and preferably with a switch on the cyclic. Initially I was going to install another micro switch on the cyclic....I have one now that changes the channels on the radio...and the other is a PTT for the radio.

I got to thinking....now thats a scary thought:wacko:.....but I decided I would just wire in parallel off my channel changing switch. It wouldnt be an issue if my radio was changing channels...as I would be doing my video recording while not in need of the radio......and I could even make my "other" channel the same channel anyway if I were wanting to monitor the radio talk .

I think with experimenting and getting just the right reference with part of the cabin in the picture would give a nice perspective.

I really got to thinking about this after doing those max performance takeoffs out of my "hole" next to my stairshop last week in the R22. I can just see a nice straight ahead max performance takeoff....with the front of the skids or the belly of the cabin in the picture as it follows an angle just clearing the tree tops....then leveling off and increasing airspeed.

Videos coming through my chopper channel would be fun to take.

Just kind of sitting here dreamin.....

Stan

choppergabor

10-29-2009, 05:55 AM

Oh yeah the "dreamers" are the ones that take this world moving to the next level :)

Al_Hammer

10-29-2009, 07:52 AM

Stan, here is a post (http://www.rotaryforum.com/forum/showpost.php?p=58622&postcount=7) describing my custom Helicycle grip with seven functions.
It was a lot of work, but I was pleased with the way it looked , at least. I never got to actually test the design, since I sold my kit a number of years ago(without the custom cyclic and custom rotor tach of my own design..

I also like the way the Jet Ranger has functions on the collective. like this. (http://fergworld.com/articles/jetranger_collective_detail.jpg)

StanFoster

10-29-2009, 08:06 AM

Al- Very impressive! I know that anything you get your hands on turns to quality! Your helicopter, your music...your intellectual offerings here on the forum. I remember your excellent detailed post starting several years ago when I first logged on.....and I have learned a lot from them. Thanks.

Stan

Al_Hammer

10-29-2009, 08:18 AM

Thank you for the kind words, Stan. I consider myself an experimenter/inventor type and not a crafstman. Nothing holds a candle to your work in terms of quality. Like most people, I feel like shooting myself when I see your helicycle photos. :D

StanFoster

10-29-2009, 09:37 AM

Al- Speaking of shooting yourself.....here is where I can keep my Glock...under the seat cushion! Actually...I am going to make a hidden compartment to store map...tools or whatever. The compartment will actually be below where my Glock 23 is sitting. There is a nice void where a guy can put some oevernight stuff. The Helicycle is not blessed with luggage space....but when I am done I will have enough for what I need to haul.

I will of course have to consider my weight and balance before I go loading up a set of wrenches.....or 1000 rounds of .40 ammo!

Stan

Al_Hammer

10-29-2009, 09:48 AM

Stan, i am reminded of the scene in the B-52 in Dr Strangelove:
"Survival Kit Check...
- one .45 caliber automatic
- two boxes of ammunition
- four days concentrated emergency rations
- one drug issue containing antibiotics, morphine, vitamin pills, pep pills, sleeping pills, tranquilizer pills
- one miniature combination Russian (pronounced 'Rooshan') phrase book and Bible
- one hundred dollars in rubles
- one hundred dollars in gold
- nine packs of chewing gum
- one issue of prophylactics
- three lipsticks
- three pair of nylon stockings

.... Shoot, a fella could have a pretty good weekend in Reno with all that stuff."

[from: Dr. Strangelove, Or How I Learned To Stop Worrying And Love The Bomb]

StanFoster

10-29-2009, 11:25 AM

I received my N-numbers today....and slipped them on.

The one picture is the back side of my upper instrument panel. I am still missing the turbine oil pressure/temp dual guage, exhaust temp guage, transponder, and possibly a fuel flow gauge.

I changed out the temporary screws holding some of the instruments in and replaced them with some black allen head screws.

I will soon be wiring the back of this upper panel.

Stan

choppergabor

10-29-2009, 05:27 PM

How exciting Stan. You got your own N number now..... Yaayyyy :) Makes the machine official ya know.

animal

10-29-2009, 07:59 PM

looks like a real aircraft now. looking good. are those lights under the numbers?

ylf

10-30-2009, 05:36 AM

looks like a real aircraft now. looking good. are those lights under the numbers?

Looks like someone has been skipping class! Here, you can borrow my notes:) http://rotaryforum.com/forum/showpost.php?p=315835&postcount=1097

animal

10-30-2009, 05:43 AM

ok yeah I had forgotten about that post before.

dloftus

10-30-2009, 06:26 AM

What are the regulations concerning firearms and flying into a commercial airport? I have my CCW permit and was wondering how I would handle having a firearm with me when I get a gyrocopter, especially an open one where you don't have a closed cabin to lock it up in.

StanFoster

10-30-2009, 06:36 AM

dloftus- I live in one of the few remaining communist states of Illinois.....where we are not allowed concealed carry. I would bet your hide would be in the slammer if caught with a firearm at an airport without their prior knowledge and their conditions met. Stan

StanFoster

10-31-2009, 04:07 AM

I am putting the Helicycle.....aka as the "Turbinator" under this morning as I work on partially installing his umbilical cord...aka....a 9-pin molex connector.

The operating table is loaded with the necessary equipment for the task at hand.

more.......

StanFoster

10-31-2009, 04:10 AM

Emergency oxygen equipment is on standby....

Aircraft Spruce is on speed dial

My hanger office has the Rotary Forum already logged in should I need technical assistance.

I will report back later with more pictures while the "Turbinator" is in recovery.

Stan

choppergabor

10-31-2009, 03:05 PM

Lol Stan I love your posts :) Oh and I just wanted to ask you to PM me your addy if you don't mind. I want to send you something:)

StanFoster

10-31-2009, 06:00 PM

I have some of the umbilical cord wired. I wont receive my turbine oil temp/pressure gauge until my turbine arrives. So, I am wiring what I can.

I installed a terminal strip to feed the 12v and the ground to the instruments.

Also...while I was at it....I located and installed the tail rotor chip light...and the main transmission chip light. These should give me warning if an unusual breakdown of metal starts inside the gearboxes.

I am thinking of installing post lights above my airspeed and my rotor tach.

Lots of little fun things to do before the turbine arrives.

Stan

gyro

11-01-2009, 04:22 AM

Stan, while your at it....The thing that bothers me most in a helo is the tail rotor or should I say the lack of it. You seem to like whistle and bells I think it would be neat to mount a small camera pointing at the most critical part of the tail rotor. and have it linked to a small LCD screen in the cockpit. you can pick up LCD's really cheap on Ebay.

Just a thought....You know the Terminator had all kinds of HUD's giving it tuns of technical data. It was designed to survive!

StanFoster

11-01-2009, 08:32 AM

gyro- The tail rotor will be balanced with some optical equipment....and should be very smooth running. I really dont think I would be able to detect anything wrong with the tail rotor on a screen. I would imagine just seeing a blur... Unusual vibration however would be noticable by feel. .....and I would be landing immediately.

The real estate on my panel is all consumed..so even if I wanted to add a viewing screen......I dont like exterior stuff just hanging on the outside.

But, I appreciate your input.

I feel that with the thorough and constant attention my Helicycle will receive in my shop......this should keep me on top of things.

There are balance weights that keep the tail rotors pitch set for around 70 mph should you lose the control cables to it. This is setup for foot neutral inputs at this speed.

Stan

karlbamforth

11-01-2009, 04:05 PM

I totally agree Stan,

A lot of technology and cameras sounds great but will it be of any use?
I also had this thought when you mentioned chip detectors, all gearboxes will make debris, sometimes at a high level for a few hours after manufacture then it slows down. The gearbox still makes debris all through its life, thats why we have a TBO. Its important that you know what level the chip detectors will indicate a problem. If it lights up for normal wear and tear the panic of trying to land after seeing a flashing chip detector may be more dangerous than what it has detected.

The reason I didn't comment earlier is because I know you have already thought of this and I only put it out there for others reading this thread.

We have a similar problem here, all our aircraft are FADEC controlled and if anything goes outside its normal parameters a red light appears indicating ECU FAIL the pilots declare an emergency and return to base telling me the aircraft are unreliable. A quick look at the computer normally shows something transient like low fuel pressure for 0.2 seconds or overspeed of 10 RPM for 1 second.

It all sounds great but if you were flying a non FADEC aircraft the pilot would never even notice these minor transient blips that happen all the time. Using the word FAIL instead of caution doesn't exactly help as the pilots think something serious is about to happen.

ooopppsss back to topic.

Keep it simple, too much information that is of no use is just as bad as not enough information.

StanFoster

11-01-2009, 04:30 PM

Karl- Good post. I am trying to keep it simple. Those chip detector lights are up high where I will see them come on. I will follow my R22 training , and if one comes on, and if it is accompanied by an unusual noise or vibration, I will land immediately, but if not, I will land where its more practical to check it out. I am using these chip detectors as just a foretelling of a possible problem. Thanks again Karl....I appreciate and respect your level of advice. Stan

dabkb2

11-01-2009, 04:57 PM

Hey Stan, here are some pics of a helicycle build at El Mirage. Rob is ready to start wiring and hopes to be flying by the first of the year.

StanFoster

11-01-2009, 05:08 PM

Dave- Thanks for those Helicycle pictures. I am in the opposite situation....I am wiring and waiting for my turbine.

I noticed this guy has the chrome exhaust like I have. I heard someone is making one out of titanium and it knocks off 10 pounds.

Stan

dabkb2

11-01-2009, 05:35 PM

I will let Rob know about the exaust, 10 lbs is hard to lose.

choppergabor

11-01-2009, 07:14 PM

That T62 sure looks sweet. When are you getting yours Stan? BTW any info on your blades?

dabkb2

11-01-2009, 07:56 PM

Are you still waiting for your blades, Rob is waiting for his also.

StanFoster

11-02-2009, 02:51 AM

Dave- I put top priority on getting my work done bonding those 16 doublers to my blades...and getting them shipped to Idaho. They do rotorblade machining in batches of 6-8 sets. They are machining the group mine is in now, so I dont anticipate this being a delay. But, had I goofed around, I could find myself waiting on my blades while having an installed turbine!.......................................... Gabor.........My turbine is supposed to arrive in December....I can now say next month! I am going to find a new level of excitement when that fourth and last shipment arrrives....Solar T-62 turbine, clutch, remaining instruments, and my chrome exhaust pipe. Ever since I obtained my helicopter rating to even be able to fly my Helicycle, I have noticed an increasing level of anticipation and adrenalin as I imagine being able to finally finish building my own chopper and most importantly...lift off and experience my new dimension................................ I have never enjoyed such feelings that taking on building this chopper and getting my helicopter rating has given me. Sometimes I pinch myself and cant believe it. ..... I can only imagine what feelings watching Doug first fly it will bring.......and then who knows how much more exciting it will be for me actually feeling that 62000 rpm turbine lifting my butt off the ground the first time. Looking forward to 2010. Sorry for my acting exuberant, but it isnt an act! Stan

choppergabor

11-02-2009, 02:55 AM

LOL Don't ever change my friend. It is so great to see your enthusiasm and the drive that takes you to achieve your dreams. I am looking for 2010 too. :)

animal

11-02-2009, 04:43 AM

yeah 2010 should be a good year,I know I am looking forward to it.

Dave, you need to get your friend to join the Forum and tell us about his Build.

StanFoster

11-02-2009, 01:11 PM

I have a little more wired on my upper instrument panel. The tail rotor and main transmission chip lights are done.

The transmission temp gauge is all done.

I took the 12 volt plug-in for the GPS....and cannabalized it to get the plug in wired to the back of the unit. I left a little loop of wire so I can rip the unit out of its velcro confinement....unplug it....then update the memory card or put the landcard in it and use it in my vehicle.

I am still deciding on my post lights to illuminate the ASI and the rotor tach.

Stan

StanFoster

11-02-2009, 01:14 PM

Heres my GPS being removed ....showing the plug in and loop I left for making this an easy task. The case fits real tight in the cutout and is also held with those 4 velcro discs.

Stan

StanFoster

11-03-2009, 04:00 AM

I have a headset wired with a single helicopter plug. I am trying to locate a jack for this plug. Aircraft Spruce does not carry them. Anyone know where I might try? Thanks......Stan

Gyro_Kai

11-03-2009, 04:23 AM

Hello,

is it the military type u174/U? This also runs by U93A/U. The panel mount is called U92B/U.

Google and thou may find :-).
I found plenty of suppliers in the States and even some here.

I have attached a couple of docs for finding the right one from dallas avionics.

Kai.

StanFoster

11-03-2009, 03:35 PM

Thanks Gyro Kai- It is a U174/U.

I ran a few more wires, and one more more molex connector will get the rest of this upper panel fed.

Stan

choppergabor

11-03-2009, 06:17 PM

Wow that looks awesome. Lot's of wiring. Extra wiring is always a good idea. Doesn't carry much of extra weight but when something goes wrong it is soooooo nice to have the backup wire to quickly hook up and be on your way...... Good thinking my friend :)

StanFoster

11-04-2009, 03:20 AM

Gabor- There is a little bit of wiring to this bird...but I have just been going at it at a slow and steady pace. I am just making sure my work is all done before the turbine arrives in December, hopefully the first week like they said.

Having this helicopter awaiting for me to work on it....is a big motivator to pry me away from something else I love to work on....stairways.:yo:

So.....if I am satisfied I have enough stairwork accomplished....then I will take off a little early and go wire on the chopper...or whatever needs to be done.

I am just about done wiring all I can.....until the rest of the instruments come...and I can find me a transponder.

I have a punch list of other things to start on while waiting on the turbine.

That would be a storage compartment under my seat...

Finish up my fuel lines....

Permanently attach the main windshield...

Install all the cabin screws....but leave the belly open for wiring and control access.

Find the right landing light...

Finish my headset wiring..

Install my strobes..

Put light blockers on the rear of my nav lights to make them legal...

Finish getting my paperwork to Tom Milton

Yee gad........I am going to have to MOVE IT!!!:help::plane::plane:

Once the turbine arrives.......priority will way heavily on getting that turbine bolted in place....so I can book with Doug for the 4 day factory checkout. He told me he needs about two months notice.

I am happily on track.....just so that turbine arrives next month.:yo:

Stan

StanFoster

11-04-2009, 01:09 PM

More pictures of the back of my breaker panel....just cleaned up a tad more...and a few more wires run. I have three blank wires hidden in the harness for future addons..or repairs...

My headphones arrived and I thought they had a monoplug on them...but instead were a regular set. I already had the mike and headphoanne jacks supplied with the kit...so I installed them in a handy place on the floorpan.

Stan

GrantR

11-05-2009, 05:37 AM

Stan,

Looking great! Will you have to get an endorsment in a turbine helicopter to fly your helicycle?

dennisu

11-05-2009, 08:37 AM

Stan

I noticed that you put the connections for the headset on the side of the seat pan. Any time I have a headset connection that comes from low with the wires going up beside me they get caught in my clothing or behind me when I move in the seat. I am going to use my old standard headset but I bought a converter cable to NATO plug(U174/U), like you were thinking yours was going to have,so it was helicopter standard. I bought the JT120 socket and put it at head height on my right. That way the wires can be tied to only give me total head movement without the wires dangling. Just a thought.

Kandace

11-05-2009, 09:43 AM

Stan,

Looking great! Will you have to get an endorsment in a turbine helicopter to fly your helicycle?

No Endorsement for turbine heli. Your private heli rating allows you to fly ANY helicopter up to 12,500 pounds gross. The insurance company on the other hand.....

Kandace

StanFoster

11-05-2009, 09:49 AM

Grant- Kandace best answered the turbine question.

Dennis- Thanks for your suggestion....but... I sat in the Helicycle...and I put the jacks where the headset cord wouldnt bother. There is absolutely no problem at all with where its at. I went through all kinds of test positions before I decided that I wanted it there on my right side down low. I can leave those headsets all plugged in and climb into the Helicycle from the left side and not hit a thing. I am going to mount the headset probably up high so it will be easy to grab. It works perfect for my long legs! I definately didnt want it coming out of the instrument panel of course as the cyclic would be batting it. I can run the cord up my right side...or pass it under my right leg if say the wind was catching it.....and both ways feel fine to me. I have had cords from below like this before with no problems.

Stan

StanFoster

11-05-2009, 09:58 AM

I wired up my headphone jacks underneath. The first picture shows the wiring on the right side of my ship not spiral wrapped and still sloppy. The antennae cable is still blowing in the wind. I am going to keep it seperate. The 2nd picture is the left side that is spiral wrapped and neat. I still have a couple of circuits to run...and they wil come down the right side that isnt spiral wrapped yet.

You can see the microphone and headset jack all patched in and spiral wrapped.

There is one picture of my fuel pump all wired in now...and I ran the fuel line to it. I used some of the spiral wrap around it as well to protect it from rubbing the frame. Right where it does go through the fiberglass cutout...I will have a piece of hose that just slips over the fuel line giving it further protection.

Stan

StanFoster

11-05-2009, 04:20 PM

I was checking my builders log today and I am right at 463 hours on this build.

I tend to pace myself by how many parts are available. When I built my SparrowHawk...the parts came in faster than I could find time to work on them, and my SparrowHawk builders log shows 503 hours in exactly 5 months to get it built. I still had a business to run...and 100 hours extra a month was all I could muster up.

The Helicycle build is much more drawn out and relaxing, and the largest number of hours I have put in on any month was the first month with 70 hours, one other month with 50 hours...then most months just piddling with 15-25 hours.

My logbook shows my first shipment coming late Feb of 2008. I put 70 hours on it the first month...followed by 25 hours the next...then 15...then 4. I ran out of parts...then there were just 6 hours put on the next month...followed by 6 straight months of 0 hours. My 2nd shipment arrived this Feb..and I just have done more thinking than building as I was soon out of parts again.

My third shipment which I am finishing up with now...shows me with 50 hours last month as I got heavy into the wiring.

My fourth and last shipment of the turbine...and clutch will change my mode....as now I will no longer be waiting on anything....but myself. I plan to have this helicopter ready for flight two months after I recei my turbine.......this being promised to me in early December. I will put in whatever hours it takes to do this. Winter time is when I can find 100 hours extra a month as I did when I built my SparrowHawk from mid September to flying it mid Feb.

My paperwork is being processed....Tom Milton will be handling the airworthiness as he has done so excellently on my last 3 builds. My helicopter rating is in my wallet....and I am wanting to resume flying my own aircraft after being a surface dweller since Sept. 2007.

Stan

RotoPlane

11-05-2009, 05:19 PM

463 Hours?.....that must not account for writing this thread. Shoot….I've have almost that much time comprehendingly reading it!

StanFoster

11-06-2009, 06:25 AM

These pictures are for Larry...aka Lanichol who requested to see a little closer shots of my circuit breakers.

I have one picture showing the bottom halves of the cabin spread for easy access to the wiring...and to put my camera up to snap these shots.

I was kidding Larry that I was slightly paranoid why he wanted some close up shots....:spy::p

Here they are Larry....if you want any other angles..let me know.

A good electrician tries to do it without shorts....:p

Stan

StanFoster

11-06-2009, 09:01 PM

I am finding myself on an ever shortening to do list....and one of them was to start securing the cabin. There are several screws going through the cabin into nutplates around the perimeter of the floor/seatpan.

There is one picture where there are three screws directly above the pilots head behind the main windshield. I had put those short screws in...then decided what a nice place to hang my headset off of. I sat in the Helicycle and confirmed there was plenty of room that such a bracket would not be giving me a scalp massage.

I quickly fashioned one out of.050 aluminum and replaced the rear screw with a longer one. I simply anchored this new bracket off that protruding screw. I have a handy place to stow my headset....and can keep it plugged in all the time while entering and exiting the helicopter.

Its starting to get exciting as I am now realizing that my turbines arrival in December will be the last final run to complete this helicopter.

It doesnt take that many hours to install the turbine and clutch....and I need to give Doug a two month notice for the factory checkout once the turbine arrives. I can see no reason why I cant have this chopper completed for the checkout in that short time period.

I am shooting for having it ready for the factory checkout and first flight by sometime in Febuarary. Earlier if my turbine arrives the first week of December....and still in Feburary if I dont receive the turbine till the end of December. I was promised it would be towards the early part.

Next will be the landing lights which I just bought.

Stan

StanFoster

11-07-2009, 07:08 AM

I have be wen looking for some light weight led landing lights...and found some last night. I installed them this morning...and it was a super simple..almost bolt on job. I happen to have two mounting screws for my instrument pod that I bolted them to.

The have to clear the chin window...and they do. I can easily adjust their angle and even splay them out slightly like I did.

I dont plan on night flying...but coming in at dusk, then flying though the even darker chopper channel , it will be nice to illuminate the ground better.

Next project is installing my front windshield.

Stan

StanFoster

11-08-2009, 03:30 AM

I now have the main windshield all screwed in.

I had a protective film on it that prevented the swipes that visitors make with their fingers across my dusty windshield. Why do they do that?

Now that it is raw plastic....I am going to be very vocal about keeping their fingers off? I had this problem with my SparrowHawk.....it was in the very dusty stairshop then....and constantly had finger marks across the windshield. I left the coating on to the very end.

The windshield on the floor shows the black stripe I painted on the inside of the window so as to hide the channel it sits in.

Clecoes...one of my favorite new words.. look like some kind of vortex generators on my windshield as I removed one at a time and placed a screw with an acorn nut on the inside. I individually shimmed under the acorn nut with plastic washers as I wanted it just to start snugging up...without putting undo pressure on the plexiglass. I also took a deburring tool to slightly chamfer the inside and outside radius of each hole. Just trying to minimize any stress that could cause a crack to radiate out.

After installation....I polished it for the first time...and what a difference having a crystal clear windshield makes when I look at the chopper. Its like when you get a new pair of shoes.

Next step will probably be putting on the full doors as I this bird should be ready to fly in Febuary. The doors have already been fit and their latches fabricated. I just will remove the protective coating on them and bolt them on.

I also would like to make an underseat storage box.

I can tell I am starting to get to the end of my pre-turbine too do list. My turbine should be here next month.

Stan

Richard

11-08-2009, 04:13 AM

Hi Stan,

I like the landing lights you found.

Can you share the source and/or model number information?

Thanks.

Richard

lanichol

11-08-2009, 05:11 AM

Very nice. Will you have your own fuel station? If this was on a farm, I would have about 250 gal storage in a hvy wall container like a converted propane tank.

StanFoster

11-08-2009, 05:58 AM

Richard- I will try and remember to write down the light information for you. I found them at an automotive store. I noticed this is your first post. Are you building a Helicycle? If so...please post any experiences...pictures etc.

I welcome you to the forum.

Larry- I am planning on getting a 250-500 gallon tank. It may be on wheels...I dont know yet. I will be extra fussy...making sure it has a good filter...water trap...etc......just to ease the workload of my onboard gascolator and filters.

My dad has diesel on all his farms.,...now that I can land at each tank, maybe I can just "borrow" some of dads fuel.....:spy::tape:.......nah....bad idea.....he is pretty sharp.....he knows where I keep the chopper.

I will for the fun of it be landing on each farm and fueling up .....I cant wait till next year.

Stan

utahgyrocop

11-08-2009, 07:00 AM

Stan,

I am not trying to be critical, so please dont take it that way. However, I have serious concerns about your landing lights.

I have much experience building and installing emergency lighting in police vehicles. When we place lights inside a window or windscreen we get what I call flashback. At night or even at dusk operators are effectively blinded by the flash of light that comes back into the cabin from the lights.

It is kinda like when you are in your house and turn on the lights at night you can't see out the window, but everybody can see you (when the curtains are open.)

Another way to put it is that the refraction of the light as it hits the inside of the windscreen causes the molecular structure of the windscreen to become illuminated and effectively put an opaque layer of light into the screen. When this happens, you can't see though the window!

All of that light in the cabin may also block the view out of all of your windows.

I would simply make the suggestion that you cleco in your chin bubble, roll your most beautiful aircraft :first: to the door of your shop and open the door. Obviously it has to be very dark. (But I know you are up at wee hours of the morning so it will be ok.) Get in the pilot's seat and turn on the lights. Then simply see if this is going to be a problem.

With all of the awesome work that you have done to this beautiful machine, I would hate to see you become effectively night blind because of this wierd situation.

Thank you for sharing your build and progress experience. I look forward to your response to this suggestion.

Please stay safe!

StanFoster

11-08-2009, 07:14 AM

Heath- I very much appreciate your concern....and admit you have me going.....hmmmm.

The guys all have their lights inside this chin window...and I havent heard them mention anything about it.

I will say that when you sit in the cabin....I am sure the instrument pod will blank out any reflected light that you mentioned. I know I will lose some brightness through the chin window....but this isnt really a big concern for me. I really will be using these more in the daytime ...when I am in the pattern. It makes the helicopter more noticable for the ones in front.

I seriously doubt I will do any nightime flying;...in fact I can promise that! I had the same feeling about my SparrowHawk at night. I never flew it at night except in the pattern at the airport.

I can see like I mentioned coming in at dusk...then hover taxiing through my chopper channel to find it will be even darker....and thats when these lights will help out. But again...they are really intended for daytime while in the pattern use.

Joe Loxtercamp has a dual pair set with a wig wag switch..and it really catches your eye.

Also...I know there are very much brighter lights than thus LED light...and if I were out looking for gangbangers running down alleys....I would have a bright halognen light....and would mount it outside the chin window as you suggested.

Aerodynamically, I will trade less light as this ship is very streamlined, thats why it can fly 110 mph on 90 horsepower. I would probably lose a little with the lights outside.

Thanks for your concern.......good observation on your end!

Stan

StanFoster

11-08-2009, 02:12 PM

Heath- I dont have my batteries installed yet...but I am curious how those lights will work. I will soon put some jumpers to the circuit panel and light them up.

Stan

StanFoster

11-08-2009, 03:46 PM

Heres an article explaining why Eagle R&D went with the Solar T-62 turbine.

Doug Schwochert is the person in the article not mentioned by name. I get a lot of kudos for my build thread here....and I really appreciate them. but its people like Doug that had the insight...and the ingenuity to do such a great accomplishment as him installing the first turbine in a Helicycle.

Doug will be the first person to fly my Helicycle during the factory checkout.

I am looking forward to that day, and I will owe Doug a big thank-you for doing what he does.

Stan

StanFoster

11-09-2009, 03:28 AM

Hi Stan,

I like the landing lights you found.

Can you share the source and/or model number information?

Thanks.

Richard

Richard- The LED lights are made by Optronics, they have 15 led lights each unit. They are very light, and very low current draw.

Stan

StanFoster

11-09-2009, 05:47 AM

I have to keep chipping away at this machine....I have been tired of looking at my dusty full and half doors in the corner.....so I got out early this morning and peeled the protective coating off of them, then polished and installed the right door.

The inside shot shows the inside of the right door on. I was tickled pink how clear the plexiglass is......but if you want to see me light up,,,,come into my hanger and drag a finger over my windshield if there is dust on it. I have had it happen on every gyro so far......I swear it wont happen on this one. You get out in the bright sunlight...and you can see when someone stupidly does that finger drag. It takes some polishing to get it back.

Its starting to look like a helicopter. I will be flying with half doors in the summer...but will be keeping this right full door on late into the spring and early fall. I flew my SparrowHawk a lot with the passenger door on during the summer on cross country trips. The wind noise was cut down...I could leave a map on the passenger seat...etc.

I am all charged up and am if I get enough stairwork done....I am going to reward myself with installing the main left door with the hinges......and the front chin window at the end of the day.

My stairbuilding and helicopter building feed energy to each other....I hope I dont short circuit from too much current.....

Stan

earthbnd misfit

11-09-2009, 02:24 PM

Have you heard of the product, "micromesh".? It is extremely fine abrasive cloth. It is used to polish out scratches from airforce jets windscreens. It comes in grit from 3000 to 10,000. Great for polishing cars without using pollish.

StanFoster

11-09-2009, 06:56 PM

I removed the protective film on the hinged door...polished it up...and was pleased to find no blemishes.

There are door latches that I have made, but not installed on this door.

Next came the chin window....and it went on easily.

Earthbound....I have never used that micro cloth you mentioned,

Stan

animal

11-09-2009, 07:04 PM

Looking Good Stan, hate I missed your call.

looks like your check list is getting smaller.

something tells me next summer we are all in for a lot of good flight reports.

StanFoster

11-10-2009, 02:44 AM

Tim- I am being pushed along by realizing my turbine will be here in December. Thats when I roll up the sleeves as there will be nothing delaying the completion of this chopper.

There are a few things to fabricate, but I believe the turbine insallation isnt going to be that big of an hour eater.

I will have it ready for the checkout in Febuary......and Doug Schwochert will be the man to first fly this. He needs a considerable time window to get scheduled for this checkout....and I can understand that. He is busy with his regular job. But these Helicycles are starting to hatch out all over.....and this is pulling Doug all over the country and even other countries.

Stan

choppergabor

11-10-2009, 02:51 AM

It really looks sharp Stan. It s a real heli. Now you need to get your turbine :) and the blades back. Almost there Stan almost!!! :)

StanFoster

11-10-2009, 09:24 AM

I set the nav lights that I bought from Bear Perkins to steady green and red, and lit them up along with my landing lights. I will be installing two clear ones set to the strobe function.....just havent decided where exactly I want them.

The power is coming from jumper cable through my harness on the tail boom. Thats where I will have two 680 amp batteries. My batteries will be how I balance the CG of this chopper with. Bigger pilots like myself have the batteries aft on the tail boom. Light weight pilots have the battery inside the instrument console in the cabin.

My batteries will have an external plug for easy jumping if necessary. The starter motor draws a few hundred amps as it spins the turbine up for starting.

Stan

choppergabor

11-10-2009, 09:32 AM

Cool! Now if you could just have them flashing synchronized with the music your iPod plays....... :)

Chuck Roberg

11-10-2009, 03:51 PM

I think those Bear Perkins lights are GREAT. Really bright. Steve has them on Black and even in bright daylight they really show up well.

Kandace

11-10-2009, 05:17 PM

Hi Stan, Just wondering if you noticed glare on the inside of the chin window? I recall on one of my night flights in the helicopter for my commercial how I had to shut off interior lights to be able to see out of the windows.

So I wonder if this will be an issue for you.

It is not so bad on a brightly lit night, but when it is very dark it is easier to fly with all of the interior lights turned off.

Just concerned about my friend Stan. :sad:

Kandace

StanFoster

11-10-2009, 06:13 PM

Kandace- I appreciate the concern, but as I mentioned, I will not be flying at night anyway. I never liked flying anything in the dark. My landing lights do not light up the cabin anyway...they are way under my instrument pod. These lights will be for being better seen in the pattern, and for illuminating my chopper channel when I do fly in with low light. But nighttime flying? NEVER! Stan

StanFoster

11-11-2009, 02:26 AM

Another thing on my punchlist was to install these door latches on the left door. I had to fabricate the L-shaped rod....cut them to the proper length...and drill a small hole to retain the washer and spring. These had to be able to retract all the way...and extend far enough to anchor into the cabin frame.

The plexiglas had to be slotted for these rods to go through the windshield for latching from the outside. I sighted through the glass and put some felt tip pen dots where to cut the bottom and top of the slots.

I step drilled slowly up to a 1/4 inch size...then took a dremel tool and hand carved undersize a little between the holes. A file was used to get these slots just right to guide the latch pin.

Stress relieving the edges of these oval slots is very important...so I took a fine pyramid shaped stone in my Dremel tool...and chamfered the edges.

The latches were then installed one at a time...and I would not move on to the next one until all was cool with the one I was working on. Two of them needed their aluminum bases ground at a slight oval...and even a slight bevel to tile the latch holders to the right angle.

The hours on these doors and the half doors used for summer flying took a bunch of hours to fabricate. I have over 50 hours in these two full doors and two half doors. Most of that work was done last year,,,and I actually had forgotten I had to cut these slots.

It helps to never get in a hurry on whatever task at hand you are working on. I really have benefited by not having the whole Helicycle kit dropped off at once. That would have taken extra self control not to rush steps like these.

If I have learned one thing in my stairbuilding...its not to rush "steps":p

Stan

Terry

11-11-2009, 03:18 AM

Looks good Stan.

Just another fuddy-duddy thought here.

Dremel and filing scratches can create stress risers in plexiglass. One way to take them out is through polishing . . . a lot of work . . . but another way is to lightly torch the edges of the plexiglass until they slightly melt, taking on a clear look.

Take it with a grain of salt. Might be worth asking around about.

StanFoster

11-11-2009, 04:00 AM

Terry- Thank-you......I will take your advice...anything to keep this stuff from cracking. All the holes in my windshield were drilled with a dull bit...they were actually melt drilled so to speak...then I chamfered the edges.

I can reach in there with my dremel and polish it. It is already finely stoned, and I think it would be ok, but whats another bit of time?

Stan

choppergabor

11-11-2009, 06:36 AM

That is a good idea Terry it does work well in some cases. Looking at your L shaped latch Stan I would rather recommend buying car door weather channel and run in on the inside of the cutouts. The rubber will give it a surface contact relief.It also helps with the cabin sagging misalignment problems that occur with helis. Just a tip :) Looking great my friend, can't wait to see you spin her up.

ylf

11-11-2009, 07:21 AM

Did you get a new camera Stan? I'm enjoying taking in all the detail with the larger pictures you're posting lately. February will be here before we know it!

Mike

StanFoster

11-11-2009, 07:28 AM

ylf- Its the same camera...but a better operator!! I finally learned its better to take 1.2 meg pictures...an resize them...than to take 100k pictures and post them quickly.

Terry- I took your advice and and smoothed out the holes in my plexiglass.

I heated a 1/4" bolt and inserted it in the slot...and melted the surface slightly. It has a slick smooth surface now..and the most important is the smooth 1/4" radius holes at the end.

I will post pictures tonight when I resize them.

Thanks again Terry..once something is pointed out to me...and I can see it..it becomes priority number !.

Stan

Passin' Thru

11-11-2009, 09:58 AM

Stan, for what it's worth, I "heal and seal" raw edges and holes in plexiglass or lexan with acetone or plain old laquer thinner.

For holes I use a "Q"tip and just swab the inside edges of the hole. Position the part so any excess will run off the edge rather than across the main area. Same with outside edges, try to position part so any excess will run down edge. just leave it to dry (evaporate) naturally. The acetone desolves the edges, melting the material and leaving a smooth, clear stress-free edge.

ckurz7000

11-11-2009, 11:04 AM

Stan, I must be not getting something here so excuse my dumb question. But if there are four latches to a door, do you need four hands to operate them? I guess you have to raise each latch in order for the door to hinge open, right?

-- Chris.

StanFoster

11-11-2009, 11:31 AM

Pete- Thanks for the acetone tip...I will use that next time...sounds even better! Either way...I have a stress relieved..and smooth edge.

Chris...you pull the latches from the top down. My door has a slight spring out to it...just enough that when you pull the top latch...it springs half a pin so ais to keep disengaged. Same as you move down to the next latch. Its real secure and easy to do. Not as simple as a one handed latch...but its fine for me. Its easy on the inside of the cabin to lock it down. I would rather have those four secure pins just in case the hinges let go....

Stan

choppergabor

11-11-2009, 12:00 PM

LOL Thanks Chris asking that question I was wondering of that myself too. Now you took on the burden of being seen as dummy not me :) Thanks :) Hint hint Stan Pictures of the operation of your latch....hint hint

StanFoster

11-11-2009, 06:21 PM

Gabor- The first two pictures are for your request. Those L-shaped pins operate easily..and they also will pivot....which got me to thinking that I could actually make a detent in the plexiglass so I could have them stay retracted. I will just see how much fuss they are later on. I heated that rod to melt the surface smooth to relieve the stress.

Stan

StanFoster

11-11-2009, 06:31 PM

My picture quality has been kind of quality challenged the last several months. I am receiving some comments noting that my pictures are much better now. One request was to show some closeups of the tail rotor again and the swashplate....so here thay are. Sorry for the poor quality shots in the past.

Stan

StanFoster

11-12-2009, 04:41 PM

Now that my winter full doors are done...I decided to get the half doors out and have them checked off. Most of the Helicycles fly with these half doors.

I made another set of hinges for these doors so that just two bolt and they come off.

I peeled the protective coating off...and all the dust went with it. A little cleaning up in the corners and they are pristine.

These half doors are nice as they keep the wind off of you.....and yet the cabin stays cool. I will probably fly with the full door on the right side, and this half door on the left side most of the year. In the warm part of the summer, then the right side will be a half door also....and when its real cold...both the full doors will be on. I will fly this beast just like my SparrowHawk, year round.

Stan

StanFoster

11-13-2009, 02:52 PM

I have the half door installed on the left side now. The latches had already been adjusted last year....and it was just a bolt on item.

This left door will remain on all year,,,,until real cold weather, then the fully enclosed door goes back on.

Stan

All_In

11-14-2009, 10:36 AM

Way to go Stan!!! Dang I've been away and look how the mice play; 98,000 hits on this thread, WOW!
I was thinking of more fun to have with a contest to see who could guess when your thread would reach 100K but now it any day. Maybe 110K?

StanFoster

11-14-2009, 01:29 PM

My two bottom fuel tanks have their pickups about 2 inches above the V-shaped bottoms, then are connected together with cross overs. I have these going to a gascolator to remove any water.

I have been thinking for sometime about tapping two fittings into each of these tanks at the bottom of the V, then putting small petcocks on them,,,effectively making two very nice sumps to really be able to control foreign material...water, etc.

The pen in the one picture is the lowest level these tanks will drain before my sump kit was added. Now I can have another 1.5 inches lower than the fuel outlets...where I can dump the fuel and test it.

I custom ground a bit until I could just get the rubber grommet through the hole,..and also put the fitting inside it.

I was a tad concerned drilling two holes in perfectly fine tanks...but I wanted these sumps.

When I did drill them, each one let out probably two cups of water that was left over from my original leak tests. So, getting this out was another benefit from this.

I hooked the two fittings up temporarily and test filled them with gasoline.

After about 5 gallons was put in....I checked the fitting and all was fine. But then all of a sudden, I noticed gasoline dribbling out from under the chopper. I quick looked and my instincts just kicked in and up went hanger door...and outside went the chopper dribbling a good run of fuel all the way!

I could just see a spark setting the whole place afire. With the fuel dribbling in the rocks outside...I was safe to ascertain what the problem was. I found it , and I had stupidly forgot my fuel line was run to my shutoff valve....and the valve was on! So a quick flip of the valve, and all was well.

I mopped the gasoline off the floor...scolded myself...and then proceeded with my leak test.

I was convinced that not one drop was going out anywhere...and so left it overnight. I got out at 6 this morning...and everything was dry as a bone.

So, I am ready for adding an in the cabin sight gauge as I trust them over anything. I didnt even put in a fuel gauge in this chopper...as I just prefer an in cabin sight tube. I have an excellent place for one that I can monitor from full clear down to when I SHOULD get it on the ground in 5 minutes.

This sight gauge will be my next project on this chopper.

Stan

animal

11-14-2009, 02:46 PM

Looks good Stan, that is going to be one sweet machine when you are done and with all the attension to details it should give you along time of good service.

it will for sure be well worth the wait and time put into building it.

Vance

11-14-2009, 02:47 PM

I hooked the two fittings up temporarily and test filled them with gasoline.
Stan

Hello Stan, why did you fill a fuel system designed for diesel with gasoline?

I would think if you are checking for leaks you would do it with Jet A or diesel.

Thank you for sharing your adventure, it is a good story well told.

Thank you, Vance

fiveboy

11-14-2009, 03:20 PM

Stan your build is freaking awesome!

Look at this picture. It is yours but I ran it through the free picture editor (and color corrector!) Picasa from Google.... just sayin, a build this pretty should show all her charms.

StanFoster

11-14-2009, 03:32 PM

StanFoster

11-14-2009, 03:44 PM

fiveboy- The colors in my pictures are what my eyes see when I go into my hanger. Thanks for trying to improve them...but that is not the color of my floors, walls or Helicycle! :)

Redbaron

11-14-2009, 04:05 PM

Looks like an ER hospital in there stan, very clean, are your floors epoxy painted?

karlbamforth

11-14-2009, 04:11 PM

Vance- The fuel system is designed for gasoline, it was later that the turbine engine was the engine used. so no harm- no foul. Also, I wanted to get that water out of my tanks, and I would rather burn it up in my truck, than dump water contaminated diesel in my dads tractor that costs 5 times as much. Some guys have burned a 50/50 mix of gasoline/diesel in this turbine. I also assumed that gasoline will seep before diesel or kerosene will. It looks like I have a leak free system, and I am tickled pink that I now have 2 sumps of nice size to capture water and crud. I plan on occasion filling up on some farms that I will have the option of landing at now. With this extra freedom I am going to have, I need more protection from these different fuel sources I will be tanking up at. Stan

Hi Stan,

Yes we use Gasloine to check for leaks too as it will seep throught the slightest hole.
Don't forget to check again for leaks the first time you fill it to full tanks as the physical weight of a full tank of fuel puts more pressure on the connections than a few gallons of gas.

Just a thought on the sight gauge, sometimes they can be difficult to read. It is a good idea to put yellow and black (or other contrasting colours) diagonal stripes behind the sight gauge. where the fuel level crosses the stripes the miniscus (is that spelt right) of the fuel distortes the lines and makes it easier to see the level, or maybe that should be less lilkey to miss read the level.

Try it on the bench first see if it helps.

fiveboy

11-14-2009, 04:47 PM

fiveboy- The colors in my pictures are what my eyes see when I go into my hanger. Thanks for trying to improve them...but that is not the color of my floors, walls or Helicycle! :)

Sorry Stan. I just assumed when you referenced your camera skills were challenged lately you meant the color temperatures.

In any color that Helicycle gives me a chubby.

StanFoster

11-14-2009, 05:09 PM

Fiveboy- I appreciate your effort to brighten my pictures, but the pictures I have posted are real close to actual. Stan

StanFoster

11-15-2009, 03:00 AM

Jeff- Thanks for the comment. My floors are epoxy coated...best money ever spent. I no longer need a bristle broom...but just a gym floor dust mop.

Its so neat to not need a creeper on this floor....I just lay down on my back....and slide under my Helicycle....its easier that a creeper....plus my belly has more clearance laying on the floor!

Karl- Thanks for the tip on making my sight tube easier to read. I am using a yellow tubing that is fairly easy to see....but your suggestion will have me trying various background diagonal striping. I will mainly go by timing my fuel burn...and I plan on putting in a fuel flow meter....but even with that nice instrument...my PRIMARY fuel gauge will be that sight tube where I can glance at and KNOW when I am down to my 20 minute reserve.

I am going out real early to get this done,,,and will post pictures later.

It shouldnt take long....I have my plumbing fittings all configured with shim washers so that they can mount through my seatpan...and as the pipe threads are just tightening up....the shim washers will also be mechaniically tightening on the seat pan. This will leave two hose barbs at the top and bottom that I will run my yellow sight tubing on. I found some perfect nylon clamps that fit this hose and I will rivet these to the seatpan.

Got to get to the shop!

Stan

lanichol

11-15-2009, 06:45 AM

My floors are epoxy coated...best money ever spent.

Its so neat to not need a creeper on this floor....I just lay down on my back....and slide under my Helicycle....

Stan

Stan, What was the brand of epoxy? I have heard it eventually gets brittle and chips.

Cement kills my knees, So I use remanents of pink 3/8" 4x8 foam insulation as a pad.

StanFoster

11-15-2009, 07:25 AM

Larry- 3M is the brand of epoxy I used on my floors. I have had it for 5 years on one floor and its holding up fine. you can buy it at Menards. 80 bucks will do 300 sq. ft. Stan

Resasi

11-15-2009, 08:24 AM

That is one primo little chopper Stan. A real beauty. I love the paint job and that duster logo.

Yup i'd say that would be a hanger any Virgo would be proud of. Good enough to eat off the floor.

I can see her getting some serious hours put on her right quick when she does get airborne. Great job and continues to entertain.

Yes we could mix avgas with Jet fuel, in certain proportions if required. Not above 20,000' and had to log the hrs accordingly. I think there was a time limit between 100 hr maint cycles.

StanFoster

11-15-2009, 04:51 PM

I have my fuel level sight gauge inside the cabin now. It will read from absolute full to down to just 5 minutes of flight time left.

The fuel burn rate is high on a turbine...and this makes my need for knowing exactly what my fuel level is at doubly important......otherwise not knowing for sure will not allow me to use the full range of my tanks safely....but rather I would be conservative on my estimated fuel left and would probably be landing with 3-4 gallons more that actual just to be safe. I just never will trust any electrical gauge. Even with my fuel flow gauge that I may install.....this sight tubing will be my PRIMARY inforrmation source.

The second picture shows me marking for a rubber hose sleeve that I Dremeled through the cabin. The sight tubing goes inside this rubber sleave so as to not have the cabin hole wearing on it. Its better than a grommet.

I used a brass elbow with a nipple...and sandwiched another elbow on the other side of the seat pan. Shim washers were used so that as the sealed pipe threads were pulling tight...it also was clamping tight on the seat pan.

I experimented with grounding down a bit for the pipe fitting to fit into the seatpan. Thats the board with the progressively smaller holes drilled until it was just nice and snug.

It took a few attempts to get the right washers in place. Anyway...the fitting are tightened to each other and are mechanically locked to the seatpan making a secure start for my sight tubing.

I did the same sandwich technique at the top fitting...and then vented it back.

I will eventually fill the tanks with exact amounts and have this very useful aid along with me monitoring how much fuel burn I have left.

Stan

Kandace

11-15-2009, 04:59 PM

Passin' Thru

11-15-2009, 05:10 PM

Stan, Is your sight gauge yellow? I only ask because Jet is is Clear or Straw colored and yellow may make it difficult to see.

Kandace

By the way, I'm loving this build. You are the consummate craftsman!

Stan, if the fuel color presents a visibility problem, you can put one of those little red plastic float balls in the sight tube like Bear Perkins sells... ?
Just a thought.
.

StanFoster

11-15-2009, 05:16 PM

Kandace- Glad you are enjoying this thread! Its comments like that and many others that keep me posting. I was experimenting with different colors of diesel, clear water, and they seem to show up easily to read. I have used clear tubing before and it always yellowed on me anyway. But, you may be right and then I will change it out to clear, just so its compatible with all the fuel types I will be burning. Stan

StanFoster

11-15-2009, 06:24 PM

Pete- Thanks for the floating ball tip! I never had heard of them. I most definately will check into that. That sounds like the best way to see the level. I love this site. Thanks again. Stan

Passin' Thru

11-15-2009, 08:14 PM

Stan, here's Bear's web site http://www.bearperkins.com/accessories.htm
The float thingy is about 2/3 way down the page in the fuel accessories section. It's called a "Floatee". :D He has lots of cool stuff.:yo:

StanFoster

11-16-2009, 03:20 AM

Pete- I will call Bear today. I have his strobe lights and I am pleased with them. I have his site on my computer, but didnt scroll down far enough before to see those floatees you educated me on. Thanks again....and I will think of you everytime I see the floating ball reading out my fuel level.:hail:

Stan

StanFoster

11-16-2009, 08:17 AM

Kandace- Now that I have a floating ball coming....I ordered some clear fuel line as well. To be honest....the yellow line clashes with my burgundy seats!

Now that passin thru gave me the tip about the red floating ball....I WANT a clear tube now.

Stan

StanFoster

11-16-2009, 03:26 PM

Part of getting this Helicycle hatched out is getting its documents back from the FAA....in other words...the birth certificate.

I am amazed at how smoothly all the paperwork for this Helicycle went through. The N-number reservation, thru the N-number assignement, thru the FAA registration....all just took a few weeks.

Tom Milton will be doing the airworthiness certificate early next year....and if he blesses this machine with his signature....then all is done. I can remember my Air Command taking f-o-r-e-v-e-r to get all this done.

I am typing this to pass on what I think made my SparrowHawk registration and now my Helicycle registration go through painlessly and very fast. After I had my N-number reserved, I applied for the assignment. I simply sent back a copy of the FAA paperwork that they sent me, along with my request for assignment.

I received my assignment in just a little over a week.....and again I sent a copy of my assignment papers back with my registration.....and it was less than 10 days I had that very important document in hand.....one of my four required documents to be onboard at all time.

I have heard of horror stories getting this done.

I had e-mailed Tom Milton for any advice , and he promptly responded to not forget the $5 check.....and to fill out it exactly as he told me. Thanks Tom, it went through like lightening fast!

Stan

Redbaron

11-16-2009, 04:15 PM

speaking of floating balls, how do you monitor fuel level on a gyro, do most install a fuel guage? I thought about some sort of mirror mounted to the seat on my bee!

Chuck Roberg

11-16-2009, 04:21 PM

speaking of floating balls, how do you monitor fuel level on a gyro, do most install a fuel guage? I thought about some sort of mirror mounted to the seat on my bee!

Most use a clear fuel line on the outside of the seat tank. One fitting is on the bottom of the seat. The other is on the side close to the top of the tank.

If you want to see the fuel level better. Then use a floatee.

Some use an electronic fuel gauge. But if your trying to keep your Bee light use the tube.

Redbaron

11-16-2009, 04:24 PM

fuel tank will be under the engine! :rolleyes:

Most use a clear fuel line on the outside of the seat tank. One fitting is on the bottom of the seat. The other is on the side close to the top of the tank.

If you want to see the fuel level better. Then use a floatee.

Some use an electronic fuel gauge. But if your trying to keep your Bee light use the tube.

Fl90

11-16-2009, 06:03 PM

When it gets quiet.....you ran out!

Seriously, though. I have a 10 gallon on the Bee here, the first gallon mark: NOT a gallon. It's about 2/3 of a gallon, and at cruise rpm, it dissapears fairly quick. On the bright side, the pick up tube was well placed.

Phil

Fl90

11-16-2009, 06:05 PM

I use time in flight vs. gallons before takeoff. Also, look back at the tank. Rick Martin used a mirror.

Fl90

11-16-2009, 06:12 PM

My appologies, Stan, for a brief stray of topic. A wonderful job.

Phil

animal

11-16-2009, 06:39 PM

Part of getting this Helicycle hatched out is getting its documents back from the FAA....in other words...the birth certificate.

I received my assignment in just a little over a week.....and again I sent a copy of my assignment papers back with my registration.....and it was less than 10 days I had that very important document in hand.....one of my four required documents to be onboard at all time.

I have heard of horror stories getting this done.

Stan

Hey Stan, that one thing I like about my helicopter purchase, this one had all the Paper work in order.

don't forget to get ya one of these cool pouches for the paperwork that has to be on board.

StanFoster

11-17-2009, 04:17 AM

Tim- I have an order going in today for a document pouch like you have....and a data plate.

Speaking of data plates, I have had two extreme examples of having one engraved.

The first one I took in for my SparrowHawk....I had a jeweler engrave it. I told them to make the letters bold. Well, it came back very neatly and precisely engraved,....but it was hardly readable it was so fine. They even went back over it and it still was like something you would engrave on a nice gold ring.

So....I ordered another data plate and took it to a guy that said he could engrave it so I could see it.

I never will forget when he presented it to me.....he had engraved it with what looked like a stamping set from Sears & Roebuck, you know...where you place the square letter shank and rap it with a hammer! I swear there wasnt one letter that was in line, parallel, or at the same depth of embossment! I was too kind to the guy and graciously thanked him for the effort. There was no charge as he wanted to contribute to my aircraft. I told him I will never forget his efforts. :rolleyes:

Now, fast forward to my new data plate. I am going to contact Kim Byrns to see if she could laser etch it boldly. I know she can. She did the beautiful switch labeling for my dash.

Stan

StanFoster

11-17-2009, 10:39 AM

Can anyone refresh my memory on the requirements for an "experimental" decal for my chopper. Seems the letters have to be 2 inches tall.....and do I still need one beings its a single seat? I dont have the info in front of me, and I dont have time to surf the net for the answer till tonight.

Thanks in advance for any confirmation on the letter size and if I do indeed still have to have it on the ship.

Stan

Chuck Roberg

11-17-2009, 10:44 AM

Hi Stan

The experimental sticker is required even for a single place and must be at least 2" in height.

You do not need the passenger warning decal for a single place since you can not carry a passenger.

Here's a little more info if your interested.
http://www.sport-pilot-training.com/n_number.htm

I know the link says ultralight to experimental. But the rules are the same.

All_In

11-17-2009, 10:57 AM

Where are you placing them Stan?

StanFoster

11-17-2009, 01:00 PM

Thanks Chuck...

John- I may go vertical up the back of the cabin just behind the doors.

Stan

StanFoster

11-18-2009, 02:18 AM

Kim Byrns is going to laser etch my data plate. ....If anyone needs any labeling of their dash panel, or anything, she is the one to go to. ........Russ , glad you are enjoying this build thread. When you start your Helicycle assembly, feel free to call anytime. Just call me when you want to come to my shop to see the chopper. I would be happy to let you look it over. Stan

StanFoster

11-18-2009, 09:52 AM

Russ- I sent you an e-mail with some info, but it came back 'failed delivery' You can stop by most anytime with a little notice. Stan

StanFoster

11-18-2009, 05:13 PM

Thanks to all the interest here on the forum, my Helicycle thread just crossed over 100,000 hits. I really appreciate all the constructive comments that I have received in this thread. Its enjoying answering the questions that I receive privately from lurkers that never post on this forum. ..........You would not believe how many have been drawn to this site from word of mouth amongst other helicopter sites.........Anyway, the best is yet to come, so keep riding this chopper till it hatches late winter.......Thanks again. Stan

choppergabor

11-18-2009, 05:16 PM

Yayyyy well deserved interest! I can't wait to see the final postings as you wind her up and take the first hovering tests :) Thanks for having us along the way!

StanFoster

11-20-2009, 05:39 AM

I received a shipment from Aircraft Spruce yesterday....and all was ok..except my data plate got crunched up. I had my two Odyssey batteries packed in with them,...and the corner of one battery was bearing down on the plate. I will call them today and get another one sent.

These Odyssey 680 batteries are very deep cycle, and is supposedly the only battery that can handle 400 full discharged cycles....or 500 if discharged to 80%. These maintain 50% of their charge if sitting for 2 years. These are suppose to have 2-3 times the cranking power over conventional batteries......just what a turbine needs as it draws a lot of amps during startup.

I had some special battery holders being shipped today from Hap Miller. He has a beautiful Helicycle that you see in various magazine articles. Hap built his a few years ago...and is very busy flying it....and making accessories for it such as these battery holders. His holders will ride my frame rails...and I can adjust my CG by shifting these batteries fore/aft.

I put my document holder where I think I want it....and also took a picture of a fuel valve I am upgrading to. It has more positive detents , plus I am going to use this valve to fill an auxillary fuel tank that I have behind my seat. I wont be hooking this up till after my checkout.....and I gain experience.....because there will be a forward CG shift when filling this aux tank. I want to have acquired the "feel" for this helicopters flying attitude, before I start using this tank.

I know I will be doing a lot of cross country flights....and having an extra 5 gallons on board really extends the radius I can fly a lot. I will use this auxillary tank as a holding tank, and start transferring fuel to the main top tank which is behind the rotorshaft. This aux tank is in front of the rotor shaft...so I figure as I am burning my fuel that is aft.....I will turn on the transfer pump and empty this aux tank the very first part of my flight. This will minimize the CG shift. But...again...I want to fly awhile before I use this tank to improve my range......the go at is slowly and in small increments testing the CG shift. Its not called an "experimental "for nothing!

Sorry about my lower resolution pictures. My main computer went on the blink again....and I can not for the life of me get this other one to crop my pictures correctly.

Stan

animal

11-20-2009, 05:48 AM

Stan does it take both battrys to start the Turbine?

how did you attach your document holder?

StanFoster

11-20-2009, 06:23 AM

Tim- One battery will start the turbine fine....but....this is extra reserve for hard starts....and I am actually benefiting from having the extra weight of 2 680 amp batteries...which gives me 1360 cranking amps....compared to the single larger 980 battery. These are skinnier and each one will ride the frame rails , one on each side....The tail rotor driveshaft doesnt get in the way....and its a nice symetrical way of doing it.

I also am going to have an aux plug in back there for charging...or for during the checkout when Doug will be starting this turbine a lot....and draining the batteries.

I will have an ammeter monitoring all this too...

Stan

choppergabor

11-20-2009, 06:33 AM

Great thinking Stan. I watched time and time again the Bell 206 series having to make it either on the first crank or wire up for the jumper! They are so underpowered with that tiny battery it's unreal. Of course they have old ones in them so that matters too. But that's what happens when the owner tries to cheapo out on the bird. I'd hate to go out on a charter flight to Jacksonville and shut down not to be able to restart :( You are thinking correctly. Cold reduces the performance too and as I have heard you guys are not exactly breaking the 97 degrees nowadays :) As for the plate....... that's really bad. Sometimes a little thing like this can make a customer go away. Just use some peanuts damn it! Ready for the Turbine!!!!! Yaaayyyy :)

StanFoster

11-20-2009, 10:04 AM

Gabor- Those batteries arent cheap, but nothing like deep cycle cranking amps. I never know when I might have a misstart and be getting low on battery juice. I intend on landing at many places that wont have jumpers nearby...:eek::eek:

I am regrouping.....getting some stairwork done....and gathering parts for my next final assualt on getting this msc. stuff done before the turbine arrives next month. I am told it will be the later part of the month.....just so its here in December. Jan and Feb are my favorite two months to have a winter project. I plan on having it ready for the four day factory checkout two months after my turbine arives.:yo:

Stan

Doug Riley

11-20-2009, 10:18 AM

Stan:

Interesting points about batteries.

In the sailboat world, there's some conventional wisdom about batteries. It says that tolerance for many -- or deep -- charge-discharge cycles (on the one hand) and short-term cranking amps (on the other) are mutually inconsistent. If you want one, you must compromise the other.

In practice, sailboaters often have two or three separate battery banks. One of these is made up of batts with all-out max cranking power, and to heck with deep-cycle tolerance. This bank is used only for starting, not for running any other systems once underway. The others are deep-cycle (sometimes 6 V. golf cart batts in one or more two-battery series) and run all the other stuff during the trip. These latter batts, called the house bank(s), get discharged deeply because there's no charging going on while you're under sail.

I wonder if something analogous might be set up in an aircraft that needs a real whallop of starting power.

PR_Arecibo_DC

11-20-2009, 11:33 AM

Stan, every time I pop my head around you impresses me more... Great job on your Helicycle... I am in a hold for now...work and more work had preventing me from doing anything... but I did bought a new Harley... By the way Stan, if you ever come by in the central Texas area let me know... I will like to give you a tour of the Apache and if you up for it, give you some Simulator Time... unfortunately would not be possible to get you in the air in a real one but at least I can get you in the cockpit and let you get the feel for it with the engine crank...and let you fly it on the real simulator...

Jose

asmuzsr

11-20-2009, 12:41 PM

gyroplanes

11-20-2009, 12:51 PM

Why did you buy one of those giant data plates?????

All you need is make, model & serial

I thought you were getting one made?

StanFoster

11-20-2009, 01:03 PM

Tony- Glad to hear your testimony on that battery. I figure that with an ammeter, if I notice an alternator failure, I would shut off non esential electrical devices.....this also includes the fuel pump, as it will run wth the mechanical one on the turbine........... I had a nice conversation with Hap Miller who just shipped off my battery holders. He mentioned that these two batteries give it several starts. He is my same weight and I asked him about his cruising speed he travels at. He said theres plenty left at 100 mph, he cruises sometimes at 110. The fuel burn is also less than I have had my range figures based on, and this ship will hansle every flight I have ever made. Stan

Chopper Reid

11-21-2009, 05:56 PM

I have been using the Odyssey batteries for a long time and they do perform as well or better than what the brochure says. Mime is a lot smaller than yours but will start my diesal Nissan Patrol with no problems and they are happy to sit idle for a couple of years and still have enough charge to start an engine [suby 2.2[ without re charging.

Stan, a good choice and its all looking great !

StanFoster

11-22-2009, 07:55 AM

Passin thru- I now have a clear sight tube and one of those floating red indicators you educated me on from Bear Perkins. Thanks so much! I changed out the yellow hose and now have a red cylinder that slides up and down the hose. It will be very easy to see my fuel level. Thanks for that tip. I left my camera at home...but I will post pictures tomorrow.

Tom....I guess I thought I needed that official data plate. My bad or ordering it...but I am going to get the new one all filled out anyway with other information.

Jose- Thanks for the kind comment...and I would love to take you up on that simulator offer. If I am ever down that way...I just will have to look you up. Thanks again.:)

Doug Riley- Thanks for your input about batteries. This turbine requires tremendous amperage to start......and you can not get many starts off a normal battery. But two of these bad boys are working well for several of the Helicycle guys. I am being guided by very experienced guys that are putting a lot of hours on this helicopter....and their advice ways very heavily towards how I do stuff.

I now have a new fuel shutoff valve installed....with positive detents for off...running the turbine...or ground transfering fuel to my auxillary tank. I know I am going to like this setup, but the aux tank wont be in used till after my checkout....and after I acquire the feel for cg shifts while flying this.

Pictures later.

Stan

StanFoster

11-22-2009, 01:13 PM

Heres a picture of the floating fuel level indicator. This is so much better than trying to see the actual fuel in the hose. Thanks again Pete for that tip! I am going to put some red warning markings in that area as thats where I will mark my 20 minute reserve "red zone"

I have the fuel shutoff valve changed out and now I have a full 3/8 fuel line coming from the tanks, to this valve and on to the turbine. Some are running 1/4 lines...but I know I will be flying in cold temperatures...and that kerosene or diesel is not as thin as gasoline.

Stan

StanFoster

11-24-2009, 03:06 PM

I had to make a disconnect for my rotor tach that is in the top panel. This panel comes completely out of the ship by just unplugging one 9 pin connector, the radio, and this 4 pin connector.

Here are some pictures of the connector going together. There are some male ends that are crimped and soldered on one set of wires....and the other side of the connector takes female ends which are also crimped and soldered.

I had pre slid on two different sizes of shrink tubing...and slid one down, took some fire to it...then slid the next size larger one down....and shrank it up tight.

The plug in of course just goes together one way. I wanted one of these connectors instead of having to pull each little wire off the back of the rotor tach.....then having to make sure they are connected back right. Just "plug and go!

Stan

StanFoster

11-25-2009, 07:56 AM

I cheated and ordered these battery boxes from Hap Miller. Even though it would have been fun designing some battery boxes... I am not an aluminum welder...and Hap Miller designed these for his Helicycle. I would not have come up with something as neat and clever. Hap did a beautiful job on these. He has several after market Helicycle items that are well thought out.

I will be able to move those two Odyysey batteries for and aft on my frame rails with this kit. 30 pounds of moveable ballast.

It will be perfect for me as I am on the heavy end for the pilots and need my ballast on the tail boom.

It has a 300 amp disconnect switch with a key that keeps all power cut off.

I will be painting these white. Looks like I have plenty to do for awhile...the turbine is "supposed" to be here late December.

Stan

StanFoster

11-27-2009, 04:20 AM

I have these battery boxes all painted and trembling awaiting Saturday morning for them to be attached.

I will have a 300 amp cutoff switch on the right battery....and will leave a loop of #6 wire to handle the for/aft cg adjustment these sliding battery holders will provide. The adair clamps will attach to the longeron frame rails making this possible.

Stan

animal

11-27-2009, 04:33 AM

those look very nice Stan.

getting closer to that Turbine day. won't be long now.

StanFoster

11-27-2009, 11:48 AM

These these are the battery boxes that can slide up and down the longeron rails to adjust the CG of this chopper.

The 300 amp switch is just sitting there not bolted in.

Stan

StanFoster

11-28-2009, 06:04 AM

These pictures are not geared toward the experienced builders here..but are from a few requests to post even more detailed steps that go into building this ship.

We all start out learning basic stuff....and I still have a lot to learn. Here are some pictures of some stainless steel battery hold down straps I made to fit these batteries.

I marked with blue tape right where I wanted to make each bend. I placed these in my vice with aluminum angles to protect the strap. I just followed on around the battery fitting and marking after each bend.

If you notice there is an allen screw holding one end of the strap. Instead of just chopping off the strap below the screw...I added a little 90 degree hook such that it was loaded up when the screw was drawn tight. I figured it was a little more redundant this way...and the 90 degree hook took the load along with the screw.

I have extra slack on the tightening bolt to allow for rubber padding under the battery and if I should put some on the straps on top of the battery. I probably will slide on some of that channel rubber that will fit this strap.
Not earthshaking news...but part of the on going process as this chopper gets closer to flight.

Stan

StanFoster

11-28-2009, 06:11 AM

This is the main power disconnect I placed right at the batteries. It is a 300 amp switch...that when off...allows that red key to come out. There is a weather proof boot to go over it also.

I will leave these battery holders loose for now until the checkout. Thats when the CG will be adjusted by sliding these adjustable brackets up and down the longeron frame rails.

Stans

StanFoster

12-01-2009, 11:20 AM

I started hooking up my #6 power cables. I crimped these on , then soldered them. These + wires are going to the 300 amp main cutoff switch.

Stan

StanFoster

12-02-2009, 04:17 AM

The ship is on its own power now. Its good to see the voltmeter indicating blood pressure..I mean voltage.

While I am awaiting the turbine arrival......I need to get all this msc. stuff done.

I was checking out my systems and so far all is working except the power to the GPS. Its on battey back up.....which I planned that way. Should my ammeter indicate a discharge....I will start shutting down non essential equipment.....including the GPS. But I will still have its use for a few hours with its internal battery backup. I wired power from my GPS switch to keep it charged and thats what I have to trace down now. It could be a poor connection through the molex connector...or it could be I wired it wrong....:wacko:

Stan

skier

12-02-2009, 06:13 AM

Stan,

After building so many kit aircraft does it ever get less rewarding to see them start to come to life?

StanFoster

12-02-2009, 07:03 AM

skier- They actually get more rewarding because so far each one has been more challenging.....plus I know I am doing a much neater job than my previous wiring jobs.

I found the power problem to my GPS. I simply had the power cable plugged into the wrong port on the back of it. It just so happens to have two round holes....I looked close and noticed I needed a port with a center probe, and the one I had it inserted into had none.

My battery is now charging off the chopper battery.

Stan

StanFoster

12-02-2009, 03:51 PM

One thing about having dual batteries besides the extra turbine starting power, is having yet another redundancy for 12 volt power. I could have either one of the positive or negative posts break off, and I still have my 12 volts keeping thinga running..........................Today I filled my tanks up with kerosene. I am testing it for fuel leaks, flushing the water and minor debris out, and calibrating my fuel level sight gauge. I dumped in exactly 5 gallons at a time and made temporary marks on some tape next to the sight gauge. I will have some nice little 5,10,15 gallon labels made. I am pleased with that red floating fuel rod that shows right where thw fuel level is..........I was pleased to find that my fuel tanks hold exactly 19.5 gallons . They originally held 16 gallons. I have 3.5 gallons more than I thought! That is not counting my 5 gallon aux tank. This turbine is thirsty, and with the fast cruising speed it has, this extra fuel will extend my radius very nicely. My bladder will be ready to empty before my fuel tanks are. Stan

animal

12-02-2009, 03:57 PM

Oh looky, post 1430, Stan has his Christmas lights on... :)

looks good Stan, other pilots should see you very well.

I have not done any lighting on the Commuter H1-B yet.

Redbaron

12-02-2009, 04:25 PM

those collision lights look cool stan, are you gonna fly at night?

StanFoster

12-02-2009, 04:49 PM

Red- I doubt I will ever fly in total darkness. I never enjoyed the thought of a forced landing in the dark. My nav lights will make me easier to see at dusk. Stan

StanFoster

12-03-2009, 02:14 PM

Heres that fuel level floater that I bought from Bear Perkins. That is the best little thing I have added. I am going to have the gallons marked along it eventually.

I just did a fuel transfer test to see how long it takes to fill my aux tank with my fuel pump. It took just a few minutes....and I am not going to mess with another fuel filler hose. This aux tank will only be used on my long cross countries....and the nice thing about the way I have it plumbed ....its going to be empty when I am doing 90% of my flying.

I am now checking my free flow fuel rate. The turbine will continue to run without the electric fuel pump....but it has to have enough free flow. I am timing it right now as I type.........

Back from my test...it free flow filled my 5 gallon can right at 12 minutes....so its flowing 25 gallons an hour....more than twice enough. I changed all my fuel fittings and lines to 3/8 inch....

Stan

StanFoster

12-04-2009, 08:04 AM

I cant leave in holes in telling the story of building this chopper. Some of this is mundane, but all part of the journey.

I decided to not put a fuel flow meter in...as I like the fuel sight tube much better. I would use it to overrule whatever my fuel flow meter would be saying.

So in the hole for the fuel flow meter will go this ammeter. I picked out one that has a large needle swing...so I can detect very subtle changes in current draw...either positive or negative.

I have a voltmeter that I will be watching..but I am thinking that any slight negative current draw will show up before the voltage starts bleeding off. I can stay on top of it by shutting down equipment should my alternator start loosing charging output.

This ammeter will be one of my primary instruments .

The first picture shows the needle with no current flowing.

The 2nd picture is when I then turned on my nav lights...and just their little current draw shows an easy to detect needle movement. The more stuff I switched on...the more the needle moved of course. This seems a lot better than the dual guages where the needle doesnt have much range of motion.

The 3rd picture shows the shunt that the all the power runs through before going to all the equipment. This ammeter reads the minute voltage drop across that resistance bar.

The old fomulae....E= I x R comes to mind. A little bit of current across a little bit of resistance...equals a little bit of voltage that this ammeter actually is detecting....and converting to amps.

Stan

StanFoster

12-04-2009, 12:56 PM

Ammeter is installed...except for my black mounting screws. I am wiring the back end here.

Stan

RotoPlane

12-04-2009, 01:17 PM

I've never installed limit markers in aircraft gauges before….can that be done after the gauges have been installed?

StanFoster

12-04-2009, 02:09 PM

Ed- I put on those vinyl limit markers that stick to your instrument glass. They make them for 2 1/4 inch or 3 1/4 inch gauges. You can get them in yellow, green, white, or red......Stan

RotoPlane

12-04-2009, 05:01 PM

Ohhhh....I've just seen them inside on the card....cool, that makes sense. Thanks Stan...

StanFoster

12-05-2009, 12:50 PM

This morning I had to do some rewiring. I had originally not planned on an ammeter....simply out of ignorance at the time not realizing how important that could be on this chopper.

So, I had to do some rewiring ....to install the shunt between the battery and the switch panel. The ammeter was installed....and it was driving me nuts getting that wired where it would react correctly. It reads microvoltages across that shunt....and after two hours just on the wiring of the ammeter...I finally had success. I still dont know exactly what I did...except more than likely reversed a wire without knowing I had reversed it. I was getting a little frustrated, took all the wires off...took a break and started over. Somehow I must have had an error...and I connected it right the second time. Anyway..its all working now.

I have some pictures of a little jumper coming from the shunt to my busbar. I needed 3 #14 wires running from one lug on the shunt to the terminal board on my busbar.

It was nice to be able to pass the wires out the seam of the cabin at the bottom and do the procedure.

All systems go again.

I have some more msc. to do fiinishing the ammeter....before I feel like moving on to my fuel transfer pump system.

Stan

utahgyrocop

12-05-2009, 01:58 PM

Stan,

Earlier in the posts somebody made a comment about the precise nature of the wiring you are doing. They compared it to factory production aircraft. I would say that your work is far superior with much greater attention to detail. I am incredibly impressed with your workmanship. Watching this piece of art has been a delight to observe from afar. Thank you for sharing.

Stay safe.

StanFoster

12-08-2009, 01:19 PM

Heath- Thanks for the comments..... However, I have to admit to discovering just today my GPS was not charging off the helicopters power system. I thought...what is going on? I had taken the cigarette lighter power cord...cut the plug in off and hard wired it into my GPS circuit. I usually double and triple check the polarity of all my wires. Murphy paid me a visit and I had wired it backwards. My GPS was still working,..but only on internal battery power. I switched the wires around and held my breath.....it works fine now and is charging. It must have had an internal diode inside that protected my dumb mistake. Otherwise...the rest of the wiring is checking out.

I have 2 hours between stair glueups that let me work on my chopper. Today I installed my aux fuel tank transfer pump. I hooked up the fuel fittings on the aux tank...and then connected the aux tank up to my fuel selector valve. The fuel pump was turned on...the fuel selector valve was moved to aux fill.....and I transfered fuel from the main fuel tanks to the aux tank.

I was paranoid about fuel leaks and sure enough.....there was fuel dribbling out on the floor. I immediately shut the pump off..and grabbed some rags...mopped it up...and it was still dribbling! I found that I failed to connect a vent line up...and thats where the problem was. After that....I filled if full....and no leaks. I was pleased to see that I now can easily put over 24 gallons.

Like I mentioned earlier....the aux tank will be later as I gain experience. But the way I have it plumbed...the CG shift is less with the way I am going to use this tank. Again...it will be only for my long cross countries. 90% of the time it will remain empty. Thats why I like the way I plumbed it up. The standard way is to have it holding all the time....the problem is this 30 pounds of fuel is forward and causes it to be a little nose heavy. I will transfer this aux fuel to my top aft tank as I start off on a cross country. It will be empty as the aft tank is topped out. That extra 5 gallons will get me a good start on a cross country.

Stan

Stan.

animal

12-08-2009, 04:21 PM

Stan,it's Dec. bet you are getting excited to know your Turbine will be here soon.

BTW whats the news on your Blades?

StanFoster

12-08-2009, 04:59 PM

Tim- My blade grips will be milled after the turbines are all shipped out. My turbine is now due in at the end of the month. Thats ok, I have been busy getting lots of other chopper work done. When that turbine arrives, I will be ready. I had a lot more msc. stuff than I realized, plus I am doing extra stuff as I invent things to do to it. Stan

choppergabor

12-09-2009, 03:25 AM

Getting there my friend! I like the idea of the extra 5 gal tank. It gives you that extra fuel that can come really handy at times. Nothing like running out of fuel at night on a cross country due to faulty gauge...... sheeeessshhh :(

StanFoster

12-09-2009, 04:46 PM

I got a call from Blake who is building my transmission and going over the turbine. Jan 15th is the new target date for shipping my turbine.........So, just like before, I will just deal with it. I will use this extra time coming up with some more finesse projects. I just tested my aux tamk transfer system today. I timed it , and it takes 12 minutes to transfer the 5 gallons to my aft tamk. That works out just fine. With full fuel, I can depart towards my destination and 15 minutes later throw the transfer switch. ............I have a punchlist I will be working on until the turbine arrives. ........My extra waiting will just allow more detail to get done, and will make me appreciate that Solar T-62 even more when it arrives. Stan

StanFoster

12-10-2009, 03:26 AM

Heres how she looks as of this morning. The ammeter is installed....the aux fuel transfer pump and switch is done.

While waiting on my turbine...this last month had me finish my pre-wiring...fuel sumps hooked up, gascolator and shutoff valve installed. Upgraded my fuel lines to 3/8 size just for more flow in real cold weather. Fuel selector valve was installed and the aux tank hooked up and all tested.

Fuel tanks are all leak tested....pump flow checked....fuel sight gauge installed and calibrated.

I was running short on my punchlist , but news of a few more weeks delay caused me to start another one which I am sure I will add to as I look over the chopper.

Since my turbine is being delayed a few more weeks...I sat down this morning and made out that new punchlist of things to do. It ran onto two pages! I need this month anyway. I am going to get all the small detail stuff out of the way so I can get that turbine installed asap when it arrives. :yo:

I can see the end coming, and this part I will miss. But the adventures of flying this machine are the best to come. Plus...a helicopter requires more maintenance...so I will always have something to piddle with. :whoo:

Stan

animal

12-10-2009, 05:03 AM

looks good Stan, yeah I think your list is a bit longer then mine now. my biggest hold up is the weather. even my test Pilot called last night to see how close I was.

choppergabor

12-10-2009, 05:50 AM

Looking almost ready to fly Stan.....oh wait...blades an T62???? LOL I know you can't wait to get that turbine :) BTW Tim I don't remember calling you last night :)

animal

12-10-2009, 05:58 AM

Looking almost ready to fly Stan.....oh wait...blades an T62???? LOL I know you can't wait to get that turbine :) BTW Tim I don't remember calling you last night :)Gabor, would you like to be the test Pilot? I mean if you want to make a Trip to Greensboro, you are one of the few Pilots I would trust to be a test pilot.

That said, you also know if I have it at a fly-in you are at you are welcome to fly it some.

I would feel totally at easy knowing your skills are at the controls.

choppergabor

12-10-2009, 08:51 AM

I appreciate your trust Tim :) Thanks. Now we just have to convince Stan to fly with me :)

StanFoster

12-10-2009, 09:55 AM

Gabor- I am convinced. I am looking forward to Bensen Days....and flying your 269.

Stan

StanFoster

12-10-2009, 11:42 AM

In case anyone is wondering why all the detail....I have several helicycle guys watching how either to do ....or not to do.....something on their ship. I receive a lot of questions....comments...suggestions from these people and I appreciate it a lot. So, this is for feedback to me as well...good or bad.

I forgot to mention that my aux tank will also completely fill by gravity feed from the main tanks by switching my fuel selector valve. This way I can just turn the valve and my aux tank will be filled without running the fuel pump, albeit just a little slower. It will be perfect filling that tank in my hanger before a big cross country...then just topping off the main tanks with 5 more gallons. When I am at an airport filling up...I will just run the fuel pump while the main tanks are being filled. This will take just a few extra minutes to fill.

Here are two shots of the fuel selector valve in the off...and then in the aux transfer mode. 90 degrees the other way directs the fuel towards the turbine.....and this line isnt hooked up yet. I am doing leak tests even on my fuel selector valve. So far the tanks and all the fuel lines and fittings are staying drive....and my open line from the fuel selector valve hasnt let out a drop yet...except for the one time I accidently turned the valve the wrong way and heard all kinds of fuel coming out on the floor. I am going to get some labels made for this valve that says... OFF AUX Main OFF.

Stan

Stan

choppergabor

12-10-2009, 11:47 AM

That seems like a good spot to put the valve to. No accidental switching under neat the seat. Stan is there a cyclic friction thingy on the heli?

StanFoster

12-10-2009, 12:05 PM

Gabor- Yes...Here are some pictures. The knob can easily apply no friction..and varying amounts of very light friction...to almost lockup. I have had a few Helicycle guys tell me that they snug the collective friction up a little....and around 70 mph the feet can come off the pedals...and the cyclic even left unattended for short periods of time. Its not a monster.

The fuel selector valve is one of my upgrades to meet my aux tank filling requirements. I positioned so that when its set to fill the aux tank...the lever is unnaturally pointing into the collective channel. This will be easier on my pre-flight knowing its set to run fuel to the turbine...and not the aux tank.

Stan

ylf

12-10-2009, 03:03 PM

Stan,
I'm trying to get a handle on your aux tank setup/procedure. You mentioned filling the aux tank using a pump or gravity and you mentioned pumping fuel from the aux tank back into the main tank. Do you have two pumps or one pump that can pump both directions?

Regarding the valve, I understand that you turn the valve to a position which allows the main tank to fill the aux tank then turn it to the ON/RUN position and go fly. Then, after flying awhile you switch the pump on and pump the fuel back into the main tank but, the valve is not turned while in flight correct?

Last question - how do you determine when all of the fuel from the aux tank has been transfered into the main tanks and you're just pumping air?

Thanks for putting up with all our questions,
Mike

StanFoster

12-10-2009, 03:47 PM

Mike- Good questions...and ones I had to think of myself and work out while designing this system. By the way,....are you building a Helicycle also?

The fuel selector valve is only used on the ground. If I turn it to aux...it will gravity feed to the aux tank.....if I am not in a hurry. If I am in a hurry...then I will throw the main fuel pump on...and it fills it quickly.

There is an aux pump that empties my aux tank to the aft top tank. It takes 12 minutes to empty this tank. I will simply use my sight gauge and start the aux pump when my sight gauge shows that at least 3 gallons has been burned off...about 15 minutes of flying. Then there will be at least two more gallons burned off by the time the aux tank is empty....and this will make the aft tank close to full. If I wait to start filling it say when 4 gallons of fuel have been burned off...or 20 minutes of flying...I wont even have to worry about over filling the aft tank. Either way...I will simply watch my sight gauge just in case my aux pump goes haywire and starts pumping at a higher rate than normal.

The whole idea is to minimize the forward fuel in the aux tank by transferring it to the aft tank as soon as practical. This being said....I have been told that not doing this causes just a little nose down tendency anyway. So, this will be even better.

I will probably have a resettabel clock and time the fuel transfer....or...I may even put in a fuel pressure gauge to monitor it. I dont think running dry will urt it for a little while.

Stan

ylf

12-10-2009, 07:09 PM

Thanks for the clarification Stan. I was picturing the main fuel pump being plumbed in after the valve not before, which is what was throwing me off. Makes sense now.

I'm not building a Helicycle yet, I've been trying to convince myself I don't need one for almost a year but I keep coming back to it, and your comprehensive build thread isn't helping. :-) My main hold up is not having a suitable workspace to build it in.

Mike

choppergabor

12-11-2009, 01:48 AM

I know you have a friction on the collective but I was asking about the cyclic Stan. How does it secure if at all? I was just wondering since I couldn't see any visible friction for the cyclic. It may not need one either. I know in high winds the blades can teeter around quite a bit when parked so I am just curious. Thanks. :)

StanFoster

12-11-2009, 02:23 AM

Gabor- What is a cyclic?? Oh, you mean that lever for my right hand? Sorry, I misread your question. It does not have any cyclic friction to apply. I think the guys just tie the rotor down to the tail boom. Stan

StanFoster

12-11-2009, 01:19 PM

I love working on punchlists. I only had one hour today...so I just searched for some quickies on the list. One was to install cotter pins in my cyclic scissor arms. OK...that took 5 minutes.... I changed out the temporary screws for some nice little black allen screws on my ammeter.....another 5 minute job.

Next I mixed up some 5 minute epoxy to secure some ends on my pinstriping that never quite stuck around the door channel curves.

I had a little time left...so I hooked up a battery charger to get the batteries up to full steam.

I took a handheld radio today and taped the PTT button down on my radio to see if its transmitting ok. I drove down the road over a mile....and it started getting weak. Mind you this is inside my shop and inside a woods. My SparrowHawk would not transmit 1/4 mile.

I am having a friend come over tomorrow to do a SWR test on my radio...and see if where its at. I have never had a clear radio transmission on any gyro I have flown. This one will be different.

Stan

StanFoster

12-12-2009, 07:30 AM

Working on my punch list.....This mornings little mission was making a wearplate between the transmission and the top of one of my fuel tanks. The head of a bolt was touching the fuel tank. This ship has some tight tolerances...but that was too tight.

I cut a thin strip of aluminum...bent it into an L....radiused the edges...sanded any burs off...and drilled for safetywire.

I then pried a little gap between the tank and this plate and slid it in.

It is in tight...but also double safety wired. I dont have to worry about a hole being wore into my tank.....and this plate can easily be inspected for wear. I will make it part of my annual to remove that angle of aluminum and check for wear.

Next comes the SWR check on my radio. I will be back!

Stan

StanFoster

12-12-2009, 10:57 AM

My friend Rob Steiger brought his electrical equipment by...and he checked my SWR, power output...and frequency.

My SWR came back at 1.7.......the power output was 7.5 watts, and my frequencies were all very close. For example...122.800 came out 122.8003

So, I was tickled that nothing had to be done. Evidently the ground plane of the tail boom frame is doing ok.

Stan

StanFoster

12-12-2009, 11:39 AM

I went back to the shop and make 5 strike plates for my half and full doors.

The first picture is just the hole in the fiberglass. You can see where the paint is already getting scuffed. I wanted to clad these with aluminum so they would last and not show latch scratches in the paint.

I use scraps of luan in my miterbox....sandwich them and cut them out.

I had to bend a radius on these strike plates as the cabin opening had a 1/8 radius to it. So I bent these around a 1/4 diameter drill bit.

Used some 1/8 rivets and now they are all in...and three things off my punch list today.:yo: 535.25 build hours to date.

Stan

Redbaron

12-12-2009, 12:02 PM

Looks good, stan I bet your helicycle will be one of the nicest in the world! ? will you be able to get it through the garage door with the blades on?

StanFoster

12-12-2009, 02:05 PM

Red- Thanks! I hope I considered the height of my door opening when I built my hanger just for this Helicycle. If not, it shouldnt take more an hour each fliight to take em on and off. Stan

StanFoster

12-14-2009, 01:12 PM

I hooked up this adaptor for being able to plug in external power......This will be handy during times when the turbine is being started a lot without much charge time...such as during the checkout when the turbine gets started a lot. The amp draw is high...and even with dual batteries....having an external source connected helps out.

Stan

helipaddy

12-14-2009, 02:26 PM

Looking real good Stan! Beautiful workmanship!

StanFoster

12-16-2009, 03:07 AM

Paddy- Thanks for the comment. With the s-t-r-e-t-c-h-e-d out build that the Helicycles shipments cause, there is no pressure to hurry through this project, rather than if all the components are dropped off at once..............It gives me time to think over each task ahead, and I have learned a lot using the time between shipments to figure this thing out............

Its weird, just a year ago every part sitting in a box seemed like it was off an alien spacecraft. I would look at other Helicycles, and just be so overwhelmed with what does this do?...or why is that this way?...etc. I took pictures of stuff that made no sense. But now its all very clear. The exception still being the turbine that I am waiting for. That will definately have my head tilted 20 degrees like the RCA dog,...when it arrives. That does come from an alien spacecraft!...............

I am trying to check off an item on my punchlist every few days, but sometimes I think of something to add to it. .......I am at least getting a lot of msc extras done pre turbine delivery, instead of after it arrives. So, the extra month of waiting is actually going to be busy building and getting this chopper closer to its first startup and my first flight in it. I have what I feel is a very realistic goal of flying it before Bensen Days. What a good feeling that will be sitting at Bensen Days knowing I have something of my own to fly again. Its been since September of 2007 when I sold my SparrowHawk. I have never enjoyed NOT flying so much as during this Helicycle build, but I am looking forward to resuming a very steady diet of turning air into downwash! I cant wait to post pictures of places I will have the ability to land on. Stan

StanFoster

12-16-2009, 04:04 AM

Have to meet a client today...but had time to get my right side half door on. It will interchange with a full door ....and instead of bolting it on...I am going to make some quicktach pins for it like I did my SparrowHawk.

Much of the year I will fly with the full door on the right, and the half door on the left. When its real hot out...I will switch to the half door on the right...and when its real cold out...both doors will be full doors. These two sets of doors took a lot of hours fitting and bonding the channels to the plexiglass.....and filling in making the channel to glass look nice.

Stan

lanichol

12-16-2009, 06:56 AM

Did I miss something. What is the status of your blades?

StanFoster

12-16-2009, 08:54 AM

Larry- I have made and bonded the 16 doubler plates to my blades, and have shipped them to Idaho. They are going to machine my blade grips as soon as the turbines are sent out. I should have my blades shipped about when I have the turbine installed and all my wiring complete. There is some work on the root end of the blades, then I will polish them as close to a mirror as I know how. By then my checkout should be very close......................... There are a lot of logistics pulling this off in a timely manner. When I get my parts, getting my work done is almost guarranteed as I will simply do what is necessary to "get er done"! Stan

StanFoster

12-19-2009, 09:18 AM

Got another thing checked off my punch list. An underseat storage bin.

I kind of let stuff fall into my hands someimes. I was going to fabricate an aluminum box and cut out the bottom of my seatpan. I held off because I thought I could find a plastic box like a small tool box or a tupperware box.

It had to have a lip around the perimeter. I was in Menards yesterday...and lo and behold there lay a box that just looked perfect. It maxed out my allowable dimensions in width...length and depth.:whoo:

I brought it home and slid it in through the opened halves in my cabin frame just to make sure it looked good. With a little struggling as it wasnt designed to come in from the bottom...it popped in place and it looked perfect.

So I extracted it and layed out the cutout. A little drilling....cutting with a sawsall...a dremel grinder...and a disc grinder....I got the box to fit. I then riveted it in place....then cut a piece of 1/4 luan plywood that is supported all around its edges...so my butt doesn fall in.

I now have a nice storage bin for keeping my cabin clutter free. The Helicycle is blessed with much luggage room....so this is a big improvement. There is room on the other half of the seat for another box...but this will suffice for now. I am not planning on loading these up with much weight as I have to watch my CG shift....although I have 30 pounds of batteries on my tailboom that can slide fore and aft to adjust my CG if I was to keep a set of tools in their permanently.

The one picture showing the box from inside the fuselage is a good view. As I was laying out my wiring ,..fuel line runs..etc...I kept this space void of anything as I knew I would be dropping in some kind of storage.

Stan

animal

12-19-2009, 09:30 AM

That looks good Stan, surpising what we find in the stores that we can adapt to our aircraft.

choppergabor

12-19-2009, 04:38 PM

Hey that's a neat solution! And of course you can always toss the ziplock bag in there with the paperwork (Airworthiness, registration blah blah) and have them on board as required :)

StanFoster

12-19-2009, 06:16 PM

Gabor- Take a peak at th last photo I posted. My document holder is just under the right side door. I has the registration in it right now, and right before the checkout...with Tom Miltons blessing, it will also its airworhiness certificate, weight and balance, and operating limitations. Stan

choppergabor

12-19-2009, 07:08 PM

Oh yeah I see it now. Cool :) Ok then you can still put your .40 down there :)

StanFoster

12-20-2009, 03:21 AM

Gabor- Yep...I can put my Glock 23 in there...and all kinds of .40 ammo. I hunt squirrels from below the tree canopy with that pistol, now I can hunt above the tree canopy! I need a brass catcher though as the empties would be going through one of the rotors.

I would start a hunt squirrels with a Glock 23 thread...but God....that would stir up the anti gunners.:lol:

Stan

PR_Arecibo_DC

12-23-2009, 06:44 AM

Stan, looking good...
Is Santa going to drop a T-Engine for your Helicycle under your tree or you would have to wait until next year...?...

Happy Holidays to you and all readers...

Jose

StanFoster

12-23-2009, 06:58 AM

Jose- I will have to wait till next year...but sometime in January is fine with me. When I found out there was going to be another month delay....instead of whining about it...which I did under my breath....I just sat down and made a punch list of things to do. It grew to 2 pages. I needed that month! Heres a picture of the check lists and I am getting stuff crossed off.

I actually did some major things like my aux tank transfer pumps....underseat storage, strike plates for the doors....etc. I have added a couple more things to my list...but it should be completed by the time my turbine arrives.

This is stuff I would have been working on after turbine gets here....so I havent lost any time actually. It really wont be a major amount of work putting the engine in. I have all the wiring run and looped up with labels where each wire is going to and coming from. I even have extra spare wires for circuits I havent even invented yet.

But...when that turbine arrives......It is going to be a good day.

Stan

PR_Arecibo_DC

12-23-2009, 07:06 AM

Stan,
is the T-Engine that you would get for your heli, a T-62/63 Solar Gas Turbine Engine... If is the one that used to be or still use for the APU on the CH-47's and UH-64's let me know if you need a maintenance manual... I believe I could get it for you...but it would be the military manual...we call them TM's (Technical Manuals) and they come in in 3 cats... (-10 for day to day maint or troubleshooting) -20 for more advance maint) -30 for depo or full maint)... I dont know if it change alot but the manuals are pretty easy to understand and there are a lot of "explode" pictures of the engine (insides)...

Let me know and I try to get them on PDF file for you...

Jose

dabkb2

12-23-2009, 07:19 AM

Waiting on parts sucks, when I was building my first gyro it took 6 months to get my Mac rebuilt. Now I can do it in about 6 hours, it has been a learning curve, steep at times but well worth the journey.

StanFoster

12-23-2009, 07:23 AM

Jose- It is a Solar T-62-32 turbine like they use in the APU's and on the Ch-47's.

Thanks for your kind offer to send the manuals...but I have a maintenance manual and an overhaul manual that are tech manuals from the U.S. airforce.

If I didnt have these...I would be taking you up on your offer.

Thanks again.

Stan

PR_Arecibo_DC

12-23-2009, 07:34 AM

NP... Stan...
I just star working few months ago with an Aviation (Air Cav) unit so I got some good resources now... Unfurtunatly, I dont have enough free time, to dedicate to a build... but the lead Test Pilot is a CFII for both R and FW and is a FAA Cert. Examiner... Must of the Apache pilots already have their FAA Cert... So I am loggin few hours on a OH-58D (Bell) once on a while when ever they have a chance to take me up... So far I got 28Hrs Log Dual....

StanFoster

12-23-2009, 07:38 AM

Jose--- Thats sounds great! When you get some flight experiences..that would be nice to start a thread about.

Stan

StanFoster

12-23-2009, 10:25 AM

Heres some pictures of my vents for the fuel tanks. When I added my sight gauge for my fuel level indication...I of course had to have it vented to the fuel tank.

My aux tank has to also dump into this tank.

The return fuel from the turbine has to dump here as well.
My problem is I only have one port for doing all this.

The sight gauge cant be plumbed into other lines that are pumping fuel back into the same port into the tank because it causes pressure and fuel blowback down my sight tube. A check valve would stop the fuel from ublowing back...but the pressure in the fuel level tube would have to be above atmospheric and more pressure than the pressure of the fuel on the other side of the check valve. This would render it useless. So...my vent only lines have to have their own port into the tank to make them work correctly.

I decided to run my aux line that transfers fuel ...and the return fuel from the turbine into this same port into my top tank. The only gremlin here is that the return fuel going to the tank is also back feeding my aux tank...not a lot...but I dont want any fuel going back into this tank. In this case...a check valve is just what I need...and I ordered one today.

Here are some pictures of the return fuel lines and the vent lines. The brass T will be vented into another port I am going to install. The last picture are the loops of wire anxiously awaiting there connections to the turbine.

You can see my red floater in the fuel level line showing the fuel level. Any back pressure would cause that fuel level to read too low. This fuel level will have an unrestricted vent into my fuel tank...with no fuel being pumped into the same port which would mess with the indicated fuel level.

This is simple stuff...but too easily overlooked. I already had my vent lines run..and I started thinking about the way I had it hooked up. I then ran some tests and sure enough...the fuel level was reading much lower when I had fuel being transferred above it. Lots of little things to ponder and think about. One thing...it causes you to be very aware how the systems all work and reinforces my method of always testing for such bugs.

Stan

Gyropilot007

12-23-2009, 01:28 PM

Stan:

I have to give you credit on paying attention to the details...you are going to have an outstanding machine once it's finished and flying.

Bob

StanFoster

12-28-2009, 11:50 AM

Bob- Thanks for the comment. I will be so happy for you when you get your machine flying again.

I love this gascolator and how I can drain the sump and check it so easily. I have been working a little bit of water out of the system. I originally filled these tanks with water to test for leaks. Now they are full of kerosene. The two lower sumps are the main traps. I could actually dump one cup of water in each tank and it would not reach the main fuel outlet. Those two sumps can then be drained also with their own petcocks.

I am going to be very picky on keeping my fuel clean...and I am also going to put a few drops of anti- algea stuff in my tanks.

I also made some brackets and mounted my two strobe lights onto each battery box. It is the most prominent position on the helicopter, very minimal blind spots for the flash. I have Bear Perkins units on there that have 18 different flash patterns. They are bright. I used the flash sequence that has mult-fires....then just a slight 3/4 second pause. The flickering flash...combined with the on and off catches your attention.

Stan

choppergabor

12-28-2009, 12:10 PM

Looking good Stan! Checking the fuel is the first step on the checklist :) I personally don't put it back into the tank..... oh yeah and I also don't give a rat's ass about not throwing the stuff on the ground.... it is biodegradable in my book :)

StanFoster

12-30-2009, 10:36 AM

My little check valve arrived...so I quickly installed it in my aux tank outlet line. This line tranfers my aux fuel to the top tank...but the problem is that the return turbine fuel goes into this same port....causing a little back flow into my aux tank. It would eventually accumulate some fuel....how much I wouldnt know until I tested it. This check valve will stop any back flow from going into my aux tank.

On pre-flight....I will just turn on my aux tank pump. I can tell if this checkvalve isnt doing its job.

One other thing I changed is my top vent coming out of my aux tank. I changed it to a clear hose so that when I am filling my aux tank with the main fuel pump....I can easily see when it is topped out....the fuel runs up this clear vent hose and dumps into the top tank. I dont have to listen to see if the tank is full.....just watch this vent line for fuel flowing.

Little quirks I am massaging out of this beast while I am awaiting my turbine.

Stan

StanFoster

12-31-2009, 02:53 PM

Just about to the end of my punchlist of stuff to get done before the turbine arrives. I actually did a lot of stuff that would had to have been done after the turbine installation...but while waiting...might as well be working on it.

The side shots shows all the wires hanging ready to be hooked up to the fuel controls....governor...and other turbine stuff.

The under the transmission shot is an oil line that acts as a cooling for the transmission oil. I have a much larger one that I may put on if my oil temps are reading a little warm.

The tail has all been checked over and safety wired as needed. There are just a few items left to do.

Stan

animal

01-03-2010, 05:54 AM

Well Stan,I bet you are getting excited.

if I remember right your Turbine should be on it's way to you soon.

really looking forward to this years reports on the Helicycle.

2010 looks like it's going to be a very exciting year for you my friend.

Can't wait to see the details of your Turbine install,not to mention pics of your baby with the blades mounted.

yep 2010 is going to be a good year.

StanFoster

01-03-2010, 06:01 AM

Tim- The feelings I experienced flying the R22 were very much intentionally understated. I do not want to make people gag. I know how I felt....and I am preparing to be nothing but ecstatic flying my own helicopter.

We all are excited about our rotorcraft....and I cant wait experiencing another dimension my helicopter will open up to me. You just have to experience it...either you love the extra capabilities...or you dont.

Stan

animal

01-03-2010, 06:12 AM

Stan I am very much looking forward to reading of your adventures in your helicycle, I use to really enjoy reading of your flights in your RAF-2000 and in your Sparrow hawk.

it is going to be fun to ride along on your adventures as you learn your machine and explore new places.

LARRYEBOYER

01-03-2010, 07:42 AM

Stan, when we talked last week, I did not have the full picture as to how far you are along. It is lookin good. Congrats and a truly happy and prosperious new year to you. It is awsome when you dream something, then work to make it happen.

StanFoster

01-07-2010, 07:27 PM

Larry- Thanks and I appreciate your comments.

I am twiddling my thumbs right now.....I have my two page punch list complete.....I am anxiously awaiting my turbine which is "supposed" to be this month. Eagle R&D does excellent work, Blake is very particular. I would be more concerned my parts getting to me way ahead of schedule than behind somewhat. They have their share of logistics to work out , and I know when it arrives...it will be done right.

Stan

StanFoster

01-09-2010, 12:25 PM

I decided to polish my tail rotor blades today. I was all set for about 3 hours of polishing...then I remembered I had bought some of Ernie Boyettes Purple stuff. I tried a little bit and was amazed at how easy it was to turn the tail rotors blades into a mirror finish. A few remaining dingy spots keep getting more mirror like each application. I will use this stuff on my main rotor blades as well. Thanks Ernie and Mike for the tip. I will start a thread just for this product as there seems to be a lot of aluminum on this site.

The second picture is the tail rotor blade before I started. It took all of a half hour to polish both sides of two blades.

Stan

utahgyrocop

01-09-2010, 01:20 PM

Now you just need main rotors and a turbine...you'll be flying before you know it!!!

Looking great Stan.

Stay safe

Gyro_Kai

01-09-2010, 01:53 PM

That turbine better be there quick or you polish it into oblivion.

No seriously, just when one thinks that's it, you put another icing on that build of yours. Fantastic.

Kai.

StanFoster

01-09-2010, 02:08 PM

Heath- Yea, all I need is that turbine and I will be busy finishing it up. ... Kai- I have no choice but to polish on it now. It really wont take that long to finish it up. I have been doing the finesse stuff that would have been left till after the turbine is installed. Stan

animal

01-09-2010, 08:25 PM

Looking good Stan, whats that Polish cost? I would not mind trying some on my blades.

akoschier

01-09-2010, 09:09 PM

Stan,
Happen to read over a recent post of yours & get the notion you are planning for a "fuel return" from the control.
There really is no such thing. The fuel pump has a pressure relief but this relief re-introduces the excess fuel to the pump inlet - i.e. its being recirculated. No tank return.
You must be thinking about the fuel pump seal drain. Its there so the leaking fuel (none by design) does not get thrown into the oil sump and screw up the lubrication system.
See, the fuel pressure is several hundred PSI and will easily overpower the seal to the accessory gearbox should the seal on the high pressure side starts leaking.
BJ has it in his video -but what this really is - is a seal drain from the fuel pump.
Normally this should not leak but once the carbon face seal starts to leak it will come out of this port.
If you looked the ships over at Homers you will find that most just dump this overboard.
This at lest tells you that the seal started leaking.
Plumbing the to the tank will keep you in the dark.
I understand you have an overhaul manual. Look it up.
avk

StanFoster

01-10-2010, 02:08 AM

akoschier- Hey...thanks for enlightening me on the fuel return. I learn a lot by working on this build....but without the turbine here, I wasnt aware of this. I took your advice and looked it up and you are absolutely correct. Thanks again.

I can understand my confusion now about this ....the build video shows a return fuel line going back to the tank. This was obviously a left over scene from another engine application......or its a modification thats been done after B.J. passed away.

I just ran this return line the other day...wasnt much waste of time...1/2 hour. Now I have something to add to my punch list....removing that line!

Your post is appreciated very much and it further reinforces the fact that by me opening up so much about my build....it also opens up areas I am ignorant on.....and this is one less area now.

Stan

choppergabor

01-10-2010, 03:35 AM

Wow isn't this forum great? What a great wealth of info. You never know who knows what? :)

StanFoster

01-10-2010, 03:55 AM

Gabor- Now I have something to disconnect on my Heli......

Stan

StanFoster

01-11-2010, 08:58 AM

Man....am I scratching for something to do on my Helicycle. I found these nifty decals to place near my turbine exhaust. Someday.....I will have turbine exhaust!!

Speaking of exhaust...I have a chrome exhaust pipe coming that makes a 90 degree bend. There basically is one best direction....down a little and to the right. If its to the left....it can mess up the airflow a little into the tail rotor. If its pointed up...it will cook the driveshaft and frame paint. If its pointed down....could start fields on fire......

I have noticed some that dont quite have the exhaust pointed down quite enough at it scorches the paint.

Stan

Kandace

01-11-2010, 10:26 AM

I'm about to call Eagle R&D and tell them to hurry up with Stan's Turbine! Our poor Stan is going to go stir crazy soon!

Kandace

67november

01-11-2010, 10:50 AM

Our poor Stan is going to go stir crazy soon!

you mean "STAIR" crazy :D

StanFoster

01-11-2010, 11:57 AM

I am starting to act crazy.....pretty soon it wont be an act....

Stan

JEFF TIPTON

01-11-2010, 02:06 PM

Sounds like Stan is getting wound up!:yo:

67november

01-11-2010, 02:47 PM

sounds like Stan is in need of spooling up!

StanFoster

01-11-2010, 03:50 PM

My turbine is supposed to be shipped close to the middle of this month. I am going to call probably the end of this week just checking how its coming. They get a little optimistic on their shipping dates. Just so I have a turbine to chew on by the end of the month....and I will be ecstatic.

Stan

67november

01-11-2010, 03:53 PM

Aog, aog, aog, ship my engine aog, aog, aog :D :D :D

earthbnd misfit

01-11-2010, 04:53 PM

Does the turbine exhaust produce any thrust? Aiming it in one direction would it cause it to rotate the chopper?

laflyboy

01-11-2010, 07:52 PM

Hi Stan, the helicycle is looking great. I am curious as to why it is taking so long to get your turbine. Blake is working on my turbine and thinks he will be finished with it sometime this week, but I have learned not to get my hopes up. :noidea:

StanFoster

01-12-2010, 02:41 AM

laflyboy- Thanks and a big welcome to this forum! Hey, that is great news that you are about to receive your turbine, because that means mine is about ready also! Yours has been delayed for the same reasons as mine. Blake is a perfectionist....thats to our advantage. He has had to work with procuring certain parts from other suppliers out of his control.....and he is just a 'little optimistic' on his shipping dates. Blake is one heck of a guy and there isnt a fleeting thought in my mind that he is sincere when he tells us shipping dates...........I would rather have my patience tested end up waiting to receive quality assured components , than have them rushed through just to stay on schedule. .................I cant say how extremely I am impressed with this company...............I hope you start a thread on your Helicycle build. How far are you along with yours?.....What instruments, etc? Your helicopter training?.........Please feel free to join us and share your experiences here!....................I cant wait to call Blake this morning. I will report back here hopefully that my turbine is about to be shipped. I am going ti be ecstatic when my turbine, chrome exhaust pipe, and the rest of my last shipment arrives! Stan

StanFoster

01-12-2010, 07:11 AM

layflyboy- You or I will not be receiving our turbines this month. I called Blake...they are now on the last machining operation of the transmissions.

I asked him when he could realistically ship my turbine. He paused....and I was silently rolling my eyes...and he said "around the first of Febuary" . That translates into mid Febuary...and now I am being the optimistic one.

I did ask if he could go ahead and ship me my two instruments which are now in...and the start switches. He agreed to do that...plus he is sending me my operators manual. I will have some more parts to chew on for a few days....

One thing through all of this I have maintained my virtue of having patience. I just told Blake I would rather have him ship something done right and meticulous later...than run through my turbine like hes killing snakes just to get it to me on time.

Stan

laflyboy

01-12-2010, 06:23 PM

Hi Stan, I agree with you. I told Blake yesterday that I would much rather have it done right than me have to fight with it after I got it. To let you know, I bought an already built ship from Tom Sled, and he still has his web site up that showes his build (www.helibuilders.net). I had problems with the turbine, which ended up seizing on me. We had to buy a new turbine and rebuild the gear case. Blake ended up taking the new turbine apart and put new seals and orings in. He now has it on the test stand, and is working on get the oil pressure down to an exceptable level. :noidea:

animal

01-12-2010, 06:26 PM

Tom also has several flight vids on youtube. that is a nice machine.

laflyboy

01-12-2010, 06:52 PM

Thanks, I got really lucky. The Helicycle is an awsome helicopter, I just had bad luck with my turbine. I can't wait until I get it flying again. I have visited with several other helicycle owners with several hundred hours on theirs with no engine trouble. :peace:

StanFoster

01-13-2010, 05:06 AM

laflyboy- Hey, I just assumed you were in my builders group #5...thats why I told you you werent getting your turbine this month. I didnt realize you had bought Toms machine. I called Blake yesterday and had my hopes up because you said your turbine was going to be shipped in a week. When Blake told me it would be around the first of Feburary....I mentioned that someone was told their turbine was shipping out in a week. He told me none would be...but of course was talking about my builders group #5.

Do you already have your helicopter rating? I am looking forward to your flying experiences...and please feel free to post a thread on your Helicycle. It would be interesting to me seeing whats involved in putting your turbine in.

Stan