Helicycle Hatchery

[Chuck Roberg]

Stan, I'm happy for you that you finally have your last build piece.

I know it will not be hurry up time now. But will be Stan time. And Stan time equates to a beautiful build.

[Kandace]

WooHoo! More build thread!

Kandace

[Cowboy]

Do I understand this correctly?

You waited 6 months for a turbine to be assembled for you...just so you can disassemble it................................................ .....to paint!

:)

[StanFoster]

Robin- You got it! Ha. Kandace, I will resume the final work to get this project complete. Glad you enjoy it! Chuck...Thank you sir! Gabor and all the rest, big thank-you. All the build threads are interesting as heck to me. Everyone has head scratchers, and watching all these build threads causes bits of information loaded into my brain, for future use. Kind of like a squirrel storing away nuts! You all know why I love eating them critters now. Stan

[kstorm32]

Stan


Did you take pictures of the governor box build.

Ken-

[All_In]

This is the clutch engagement system. The electric motor runs the screw to engage or disengage the drive belts. The parts with the tuff rubber on them are part of an over center apparatus that locks in 300 pounds of pressure. Micro switches are activated at both ends of the screw drive which trips my engage and disengage lights on my dash.

The drive screw is run by a DPDT switch....and when you start out engaging it...the first button is used which is limeted by a 10 ohm resistor......then after partial engagement....the other switch is pressed which feeds this motor the full 12 volts for more rapid engagement. Pretty slick and simple in my opinion.


Stan
I understand from the verbal description how the clutch works, but not from the pictures. When you put this back together can you show me a picture? I see the motor not the switch or how it's attached.

[kstorm32]

John

the clutch switches are on post 1730

Ken-

[StanFoster]

Ken- I will post some pictures of my governor box. It is all done. They shipped me the components ahead of time so I could keep my idle hands busy. They were very good about that, taking my calls etc. After seeing my turbine, it WAS WORTH THE WAIT! I am so satisfied with everything they have sent me. A1. Stan

[kstorm32]

Stan

your turbine looks great, I'm so happy for you.I just got my contract from Blake
and after seeing your build and you getting your turbine I think I'm going to do it.I have talked to Hap Miller who lives close to me,and is willing to help me.All I'm waiting for is my wife to sign the divorce paper,and retain my right nut.and ill be ready.

Ken-

[StanFoster]

Ken- Hsap Millers Helicycle is simply georgous! I love that guy. I bought his adjustable battery boxes.. Hap is my mentor. Stan

[kstorm32]

Blake told me that you and Hap are one of the best builder he has seen,And I will need help on some part that i don't feel comfortable building.like the rotor blades and tail fins.all the electronics ill have no problem with doing myself.Hap is building one with his son now and I'm going to get up there and take a look at it soon.

Ken-

[All_In]

Stan
...All I'm waiting for is my wife to sign the divorce paper,and retain my right nut.and ill be ready.

Ken-
Congratulations, you get a Helicycle and you get to keep your right nut?! Great exchange!!!

Lucky MAN!!!!:peace:

[kstorm32]

John

She still has a tight grip on it.The House and a hundred grand seems to be letting the grip off soon

Ken-

[kstorm32]

and I might retain 100% of my company.

Ken-

[StanFoster]

Started prepping, I primed, and then epoxied a bunch of parts and the turbine gearbox.

You can see the sacrificial hardwar store bolts holding the gearbox together. I only had to tape one off....because I would have had to take the fuel pump, fuel control valve off to get to it.



Stan

[All_In]

Looking good buddy!

So glad you are building again, we love this stuff!

@Ken
That is great news 100%! I wish you luck, living in Ca you will need it!

[kstorm32]

Go Stan go.....looks great

Ken-

[choppergabor]

Oh yeah! I love it! Stan is working instead of calling me on the friggin phone every 10 minutes or so ROFL. I like the fact that he is busy. Looking good Stan. The usual quality one can expect from you :) K back to sanding the tail...... 104 heat index.........And NO JOHN I don't care about the 81 over there............... :)

[Passin' Thru]

My high today was 85F. Right now its 77F. :D

[All_In]

I said nothing Gabor!

Thank you Pete!!!!:lol:

[choppergabor]

My high today was 85F. Right now its 77F. :D
Oh yeah? What about that storm you had yesterday? Send those clouds away for me please. I don't want them hanging around for next week. :):focus:
Stan same color as the rest right?

[StanFoster]

Gabor- All my trannies and TR gearbox are white. All the brackets etc. are also white. It brightens up everything when you are pre-flighting. My spare time is going to be split between my Helicycle, my mowing, my honey doo lists..., Summer is a tough time to get away. I left to work on a stairway at 5 a.m. This morning so I could be finished by 1 p.m. It gave me a couple extra Helicycle hours.
It keeps me hopping in the evening as I plan my next attack. Stan

[Gyro_Kai]

It is so great watching the build continue.

Kai.

[StanFoster]

Lots of little parts to paint. I am no painter, so bear with me. I only paint what I can touch up....

I had 3 pairs of pillow blocks that are definately indexed....so before I screwed everything up, I untaped them and indexed them with a felt tip pen, then covered the marks with blue tape. No paint there on these contacting surfaces anyway.

I have a row of parts hanging off my garage door track....and I am busier than a one eyed cat watching 10 mice when I start painting.

Stan

[Kandace]

I'm so excited to see this build continue! I'm so happy for you Stan! You are going to have so much fun finishing this build and then flying the daylights out of this bird!

Kandace

[StanFoster]

I had a talk with myself....and I was granted some time off to paint some parts today. I have an assembly line of parts hanging off of safety wires off my garaged door track.

There are 3 pairs of pillow blocks that have to stay indexed together...so I marked them and taped over where I didnt want any paint.

I epoxied all these parts in several steps.

I was busier than a one eyed cat watching a dozen mice!


Stan

[choppergabor]

Looking all pretty :)

[All_In]

Yes!! Stan is back to building AGAIN!!!!

Now if Tim O, Vance and Ed would start posting pictures of their adventures AGAIN all would seems right with the world!!!

Where are these guys, anyway?????

[PR_Arecibo_DC]

Stan... question?.... what type of paint are you using?... Is the heat of the engine would not damage the paint job?...

[StanFoster]

I am using epoxy paint. The geatbox doesnt get that warm. Its separated by the air intake section. Here are some pictures of the engine after I took the blue tape off.


All my components shipped the other day are now painted. I am pleased with the way they turned out. I am now wiping off some very minor overspray going onto my intake section of the turbine.


Stan

[StanFoster]

Latest update on my scheduled checkout. In case anyone is thinking I am trying to make Mentone in this Helicycle...I assure you it wont happen. Doug Schwochert who will be doing my checkout will not be doing any checkouts in July. So...even if it was ready in a week....it will stilll be until early August for my first flight.

That gives me 7 weeks to have this machine ready to fly.....and it relaxes me to know I am not trying to beat a stupid deadline. Plus...several here just KNOW I am planning on flying it in....and that just wont be possible.

So,....I have 7 nice long weeks to get this engine in and all the other msc. stuff ....and I will be ready for this to be Dougs first checkout in August.

I am looking forward to the next 7 weeks....and then the adventure really starts....but at least this build thread will be finished after the skids leave the ground with me in it.

Stan

[StanFoster]

I now have the turbine up on my workbench on wheels. I can spin it around easily and its at a comfortable height. There are several oil lines I have to fabricate...bend...flare...and hook up to the oil pump..filter..etc. Next I will be putting in the original black gearbox allen bolts...the pulley...and some other stuff I took off. Lots of fun stuff ahead....stay tuned, we are just getting started again.



Stan

[J.C.Casabuono]

The little engine on wheels over the table put me nervous,please,lock it there...

[StanFoster]

J.C. No need to be nervous, my bench is dead level. Its not going anywhere. Stan-

[choppergabor]

Stan you need to eat and sleep too! So the new slogan is 7 weeks now? :)

[J.C.Casabuono]

Yes Stan,following your work, I imagine that...just my feeling :)

[earthbnd misfit]

Nice going. Just wondering what sort of revs the stater turns the turbine, and whats the ratio between starter and turbine? Heli's are the ultimate of road vehicles.

[StanFoster]

Here are some parts fresh painted. I may let them dry for 2 weeks...just in case I want to start assembling them in July.


I took out the sacrificial gearbox and pulley bolts and put the black socket head bolts back in. Even though they are black, I painted the heads black like I have on my other projects to prevent them from rusting. Someone suggested by e-mail using stainless steel bolts....and that is a good idea. But I like the black bolts buttoning up the white gearbox. I doubt they rust , but if the do...I will either touch them up..or replace with stainless.

Next comes the oil lines that have to be fabricated and hooked up to various ports.


Stan

[All_In]

Looking good buddy!!! Nice to have you building again, really!

I'll bet JC has earthquakes in his part of the woods. Why because I'm thinking the same thing we would never leave anything expensive on wheels that rolls on a table unless we were trying to see if it would roll off during the next earthquake! Oh my...

[kstorm32]

Stan

On the tubing that you have to flare,are they aircraft type fittings?Because I found out the hard way that a automotive flare tool is 45 o, and a aircraft is 37

Ken-

[Passin' Thru]

Stan

On the tubing that you have to flare,are they aircraft type fittings?Because I found out the hard way that a automotive flare tool is 45 o, and a aircraft is 37

Ken-
VERY good point!
I ran into this in my first Piper rebuild. :sad:

[All_In]

Stan

On the tubing that you have to flare,are they aircraft type fittings?Because I found out the hard way that a automotive flare tool is 45 o, and a aircraft is 37

Ken-

I did not know that! Great info you learn here. I love this site!!!

[kstorm32]

I got mine from Air Craft spruce Co. Part #212-FB Made By roto- flair


Ken-

[StanFoster]

Ken- They are aircraft fittings....and are indeed 37 degrees. I bought a nice flaring tool from Aircraft Spruce for earlier flaring jobs in my build. If you go back about 1,345,546 pages...you will see pictures of it. Ha


Stan

[kstorm32]

Stan

It was just an FYI only.I did not no, Till I almost Ran my new rebuild out of oil.

Ken-This is what I looked like when it happened:whoo:

O and I think I shead some tears

[StanFoster]

Here are some pictures with a dowel pointing to some fuel lines. The first picture is where the fuel comes into the pump....the 2nd is the high pressure line where it comes out....then goes to a fuel manifold and onto the 6 burners.

One picture shows the fuel contol motor and the linkage that controls the rpm's of this beast from 45000 to 62000 rpm.

The 2nd picture is the main fuel solenoid....a switch turns this on in the cockpit, and this sends the JetA to the burners.


The 5th picture is the start fuel line...again controlled from the cockpit. The next picture is where the exciter is connected to make a starting spark by the fuel inlet.

This thing seemed so alien at first...but I am amazed at the complexity of thought that it took to make a basically simple machine. I have some excellent manuals on this engine and just following the air intake into the compressor...then the diffuser...on to and around the perimeter of the burner can....then looping back into the 6 spray nozzles where all the hell fire is going on...then all this fire heads to the turbine wheel where a lot of this power is extracted to turn the turbine/compressor wheel as the inlet end is gulping in tons of air.... whats left over is that sweet whine and smell of Jet A and the miraged of the exhaust plume.

I cant wait to feel how smooth this power feels.


I have been thinking about this too long.

Stan

[Resasi]

Go away for a couple of day flying come back and you have hit the ground running with that newly delivered Christmas/Birthday present just delivered.

Delighted your full steam ahead again Stan.

[StanFoster]

Leigh- Thanks. I feel I am back in the groove. Stan

[dabkb2]

It looks pretty nice Stan.

[earthbnd misfit]

Does the turbine produce a lot of thrust, affecting control etc?

[kingo]

Hi Stan
I have enjoyed this thread immensely, glad your turbine turned up, and you could start your build again.
what percentage power, and egt gauge are you goin go use? what gearbox oil are you going to run?
sorry for all the question, got a project on the go and need to obtain a few things.


Brett.

[StanFoster]

Mike- The thrust is minimal, and is actually directed against the TR thrust. Brett- Glad you have enjoyed this build. The engine is derated from 160 horse to 90 which is a little over 60%. The gearbox oil is the same as the transmission oil. Its an oil used in high end racing applications, but I will have to look on the jug for the name that escapes me. I will also have to get back to you on the EGT gauge. Stan

[StanFoster]

Brett- The oil you were asking about is Pro Gear 21, made by Aisyn.

The EGT is by Westach. Here are some pictures.


Stan

[WindRyder06]

Wow Stan!! You are looking good.... I mean the engine assembly and helicopter is looking good. You... well, that is another story:whip:

Keep up the fantastic workmanship.

[All_In]

Yep everything is right with the world Stan is building again, hard to beleive it's only been TWO WEEKS!

And he's teaching us the system's on the turbine, he's got his pointer and everything. Yes life is good!

Thanks Stan!

[StanFoster]

I started making my oil lines to connect all the ports from the oil pump to the oil filter and back to the main bearings.

I used a 37 degree flaring tool and a tubing cutter for the lines. Takes a little time...but its satisfying work. Several more to run...


The first picture is an aluminum clamp I had to fabricate. This holds the oil filter next to the gearbox, then I plumbed all the lines to it.

Stan

[choppergabor]

Looking really nice Stan :) Oh I can't wait for the day you get to lift those skids off the ground :)

[animal]

Woo Hoo, stan is back to having fun again. looking good Stan.

[RotoPlane]

Unless I'm not viewing it right, the bottom short oil tube must be removed to change the filter element....and I assume that is not very often. Looking terrific!

[StanFoster]

Ed- Very observant. People on this forum really scrutinize the photos! I will have to take that little tubing off when I change the oil filter. Hey, any idea how many times one can take a flare aluminum fitting off and on, before its sealing integrity has been compromised?? Stan

[RotoPlane]

Because of the tube bend, the flare should mate to the fitting the same each time...and if the tube nut is not over-torqued and the same torque is used each time, it will last many cycles. I always made sure the nut, ferule and tube flare were oiled before each assembly.

[StanFoster]

Ed- Thanks for that info. My squirrel just ran into my brain with two cheekfuls of info to store away. Stan

[Resasi]

Thought they went into the stomach Stan?

This one obviously didn't get his head blown off.:)

[Flying_Lab_Rat]

Stan,

May not be a bad idea to fabricate an extra line or two if you plan on taking it loose and putting it back on again on occasion. It's easier to make them when the turbine's sitting on the table than when everything's together and it's leaking oil all over. Just the sort of thing I would do if I was building it.

Dustin

[StanFoster]

Dustin- Excellent idea! I will have a clone made if this fitting and any others and store them away. Stan

[JEFF TIPTON]

I wonder if a flexible hose would be easier to install and remove. The AN fitting would wear better.

[brett s]

Yep, I'd think about using a flex line there myself.

Depends on how often you pull that filter I guess - what's the inspection interval? Seems like we only pulled them every couple hundred hours on the T62 APU's in CH-47's though.

[StanFoster]

Jeff- Those are AN fittings, and it couldn't be simpler to take that curved line off. I have a return oil line just under the filter that I have to plumb later, and I am going to direct it away so I won't have to take it off as well. Stan

[StanFoster]

After getting back to my build again, I am conservatively saying that although there are a lot of little things to do, it really will go very steadily.
it won't take very long to get this turbine installed. I am going to do as much as I can on the turbine while its on my bench. Here is an outline of what is left to do. Bond the fiberglass halves together for the oil sump.....paint the sump....mount the sump....run a few lines to the sump...plug in 5 wiring hookups on to the turbine...assemble the clutch parts............mount the turbine into the chopper.........finish the wiring hookups..........run the two fuel lines............then they will send me a final checklist to verify everything is ready for the factory checkout that will occur just after Mentone. This helicopter should be easily ready for the checkout before I go to Mentone. I do have a 'fail safe' modification that I want to do to the main fuel solenoid. I want it to not require voltage to keep the fuel on to the turbine, but rather if there is an electrical failure in the circuit, the valve remains open. I have a detailed set of plans how to do this, and I will if the company allows it for the checkout. If not, it will be done right afterwards. ..................Anyway, I am anticipating a very relaxing but very steady wrap up to this project. Stan.

[dragonflyerthom]

Way to go Stan. Patients really is learned, We're not born with it. You could be a very good Deer Hunter. I can hardly wait to hear you have flown it.

[StanFoster]

Thom- Thanks. I love deer hunting and am looking forward to stop flying the Helicycle so I can hunt. I can see the end in sight for this helicopter. She will be flying in August. Stan

[J.C.Casabuono]

Stan,
I see that the T-62 has auto-shutdown protections like most APU's ( low oil press,overspeed and EGT).Are they disabled for helicopter use of the engine or are still enabled?

[J.C.Casabuono]

Stan,
I see that the T-62 has auto-shutdown protections like most APU ( low oil press,overspeed and EGT).They disabled it for the helicopter use of the engine or are still enabled?

[StanFoster]

JC- Good question. The main fuel solenoid normally requires voltage to remain open. So, if the circuit fails, the fuel shuts off and you auto in. The modification makes the valve fail safe by requiring voltage to close it. A DPDT switch is installed so at initial startup, even though the main fuel solenoid switch is on, this DPDT switch is off, keeping the main fuel solenoid off. When the turbine lights, the DPDT switch is thrown and now the main fuel solenoid is activated and the 6 spray nozzles receive kerosene and the turbine runs to operating rpm,s. The overspeed circuitry is still intact and should this occur, and instead of the main fuel solenoid receiving no voltage which shuts it down, the main fuel solenoid now receives voltage to shut it down. I am still thinking this through JC and I am not sure if low oil pressure also will send voltage to shut the main fuel solenoid down. That is one of my questions I am seeking advice on, and you are very astute to bring that up. I do know that with this modification, on turbine shutdown, you must remember to throw the DPDT switch off, or there will be fuel spraying into the burner can which will be more embarrasing than dangerous as it will shoot out clouds of smoke. There are many Helicycles flying with and without this modification. I am still working the logistics through my head before I decide which way to go. I just like the idea of the main fuel solenoid in a fail safe mode. Stan

[kingo]

Hi stan
thanks for the info on the gages and oil, www.mglavionics.com/ html/infinity.html these gages are priced not to bad,the RV-2 is a %power gage for the turbine and the TC-1 is a egt temp you can program a couple of different displays

Brett.

[brett s]

I'm with you, definitely would want fuel to fail on rather than off if voltage is lost - I'd also want the other protections disabled.

For an APU they make sense, for an engine I'd rather have the choice.

[HobbyCAD]

Stan,

Have you guy's thought this thing through properly, done a proper failure mode analysis?

With the fuel not shutting off in the event of a electrical malfunction, or not being able to shut it down, with an electrical malfunction, is that not the same dangerious condition? If you lose electrics, you lose the governor as well. With your mod, you lose the governor, AND the ability to tame that little fire breathing beast in the back !! My gutfeel tells me a "dead" beast is better that a "runaway" beast.

I see a scenario where the electrics fail, while you have power (load) on the engine. For starters, that little fuel arm that is controlled by the governor motor, it oscillates around a lot, and it has only to move a minute bit, to change the throttle setting. Have you watched that little arm pulse around while the engine is running? Well, in the event of an electrical failure, and all the electrics die, so does the little motor driving the throttle arm. What are the chances of it stopping with the arm exactly in the correct position, or even worse, in a much more open position. You know, it only has to move a LITTLE bit, to give a heck of a lot more fuel !!

Now my point, how are you going to get the heli down, for with the engine now giving power, or worse, too much power, if you lower the collective lever, you reduce the load on the engine, the engine is not governed any more, you will speed up the main rotor, as you attempt to lower the lever. Are you not now in an even more dangerious position, with a potential MR overspeed coming your way? If the thing stops working with that little erratic jerking throttle arm in a more open position, you are going to have to be pulling in more power, to limit the RRPM. With all this happening so fast, are you going to be able to reach for some manual fuel shut-off valve? If you do, you in any case are going into an auto, but pretty much rattled and shaken up at that stage.

Is it not better to have a small battery back-up for the electrics, and if that also fails, ride down an auto, rather than risk a potential RRPM overspeed, with potential disasterious effects?

[StanFoster]

Hobbycad- Your point is well taken and is one of the reasons I posted it. I knew I would get pro and cons on this. You have my head scratching.

I was originally wanting to do just what you mentioned...have a secondary circuit with a switch and breaker. Right after the turbine starts...I would switch this to run a redundancy power to the main fuel solenoid.

You make some good suggestions and even though the overspeed protection is still enabled.....you make a good point on total power failure. I would not want a run away engine, ungoverned. I belieev I would rather do with a backup power to the main fuel solenoid...and if all power fails....my fuel will shut off...and I would just half to auto in.

Lots for me think about....and I am going to contact some people that have done this mod with your points brought up.

Most are not modified.......

Stan

[dragonflyerthom]

I am so happy for you Stan. I will see ya at Mentone. I hope that Murphy comes with the Canadian Embassy. This year I am thinking of Tent camping there at the airport. I can hardly wait to see all of my friends.

[StanFoster]

Hobbycad- I obtained some more information........If the main fuel solenoid is modified to fail open...."not requiring voltage to keep it open"........and you are flying along and you have total power failure....the turbine overspeed is fail safe....the actuator motor will go to idle by a spring return. The turbine still will run as the main fuel solenoid is now fail safe. In the worst case scenario that the throttle return spring breaks at the same time...very rare...well yes..then you could have a runaway turbine if the throttle stuck wide open. Very slim chance this would happen..but nonetheless...a possibility.

My other option was as you mentioned...a secondary 12 power supply that was wired in parallel to supply power to the main fuel solenoid. This would be turned on for redundancy after the turbine is lit. I would think that the circuitry would need some diodes to protect the secondary power supply to the main fuel solenoid from following a short on the other side.

You cant build anything that is completely fail safe of course. So, the above two ways I am further researching before I go and modify my main fuel solenoid. I am presently leaning towards modifying it. I could still take the worse case scenario...and have a backup battery and switch that would shut off the main fuel solenoid if I had total power failure....and my throttle return spring also malfunctioned. I dont think I will go that way, because in my opinion....I would be so distracted by a power failure...and if the throttle return spring failed and I had an overspeed....I doubt I would react fast enough to shut it down.


Thom......looking forward to visiting with you at Mentone again.





Stan

[StanFoster]

I have the rest of the oil lines run...and here I have my oil sump temporarily bolted into position so I could run the three lines to it. I had to make some steel L-shaped brackets to secure it to the gearbox. It will come off next to paint.

The next step is to start assembling the electric clutch parts. After that, it will be time to get an engine hoist from the farm down here and lift this little pig into place.

My dad could not believe how small the actual turbine is...about the size of a 5 gallon bucket. It roughly measures 16 inches long by 12 inches across.

This same engine is used in the Rotorway helicopters...and are simply adjusted for 160 horses instead of the 90-95 its set at now.


The middle pictures shows an oil line running between two lines. Whenever the clearance is rather tight...I just wrap some 1/4 inch spiral wrap around the line and its done with no worries of vibration rubbing through. I did this in 3 places.

Stan

[StanFoster]

Word is out around town that my turbine has arrived and I am constantly getting drop ins just wanting to see it. I never told a soul except my dad.......hmmmmmm ....


Here is my dad who will be 90 next Feb....he is in the background. Another WW2 veteran is in the foreground, Jim Ross. Jim was at Bensen Days the last two years.

That turbine is an attractive nuisance......I have to park my truck in back if I dont want interupted on stair or heli work.


Stan

[J.C.Casabuono]

JC- Good question. The main fuel solenoid normally requires voltage to remain open. So, if the circuit fails, the fuel shuts off and you auto in. The modification makes the valve fail safe by requiring voltage to close it. A DPDT switch is installed so at initial startup, even though the main fuel solenoid switch is on, this DPDT switch is off, keeping the main fuel solenoid off. When the turbine lights, the DPDT switch is thrown and now the main fuel solenoid is activated and the 6 spray nozzles receive kerosene and the turbine runs to operating rpm,s. The overspeed circuitry is still intact and should this occur, and instead of the main fuel solenoid receiving no voltage which shuts it down, the main fuel solenoid now receives voltage to shut it down. I am still thinking this through JC and I am not sure if low oil pressure also will send voltage to shut the main fuel solenoid down. That is one of my questions I am seeking advice on, and you are very astute to bring that up. I do know that with this modification, on turbine shutdown, you must remember to throw the DPDT switch off, or there will be fuel spraying into the burner can which will be more embarrasing than dangerous as it will shoot out clouds of smoke. There are many Helicycles flying with and without this modification. I am still working the logistics through my head before I decide which way to go. I just like the idea of the main fuel solenoid in a fail safe mode. Stan

Stan, I'm sorry for the double post on my question.
I would prefer a mechanical cable operated fuel valve instead that ON-OFF powered main fuel flow solenoid valve.This way you dont need to worry about auto shut downs.
The 110% RPM protection probably is ok,but you don't want an engine death due a failed low oil press sw. or false EGT indication.
I would also install an ON-OFF sw in line with the fuel start solenoid,this way you can avoid a hot start,manually disabling that valve.
Just my thoughs,hope to help.

Juan Carlos

[StanFoster]

Juan- I appreciate yours and all the others helpful comments. I have learned a lot about this turbine, yet I have a lot more to learn. By the way, there isn't a low oil pressure shutdown or a high EGT shutdown. I have gauges and idiot lights which I will be scanning constantly as I should be. There are many of these Helicycles accumulating lots of hours. I will be in a beehive of them at Homer Bells next month. That's when I am certain I will know which way to configure my main fuel solenoid. I more than likely will be modifying it for fail safe. I play devils advocate on both sides of lots of issues, and will do the same on this one. Stan

[All_In]

To the town = oh you of little faith. And NOW... "oh they all knew you could do it"???

To dad wish you would not mention it to the one friend you trust in a small town dinner.

To Jim say HI! Oh to dad and Barb too!!!

To Stan GREAT JOB, soon the cherry picker will be needed. There is no stopping you now!!!

[StanFoster]

John- I am bringing in the cherry picker from dads farmshop soon. I have to get the clutch assembled first. Give me about two weeks and the turbine will be in. Stan

[All_In]

No no no no no no any time you say but NOT "TWO WEEKS"! it's 14 days from now on I cannot take it any other way!!

[asmuzsr]

In all fairness, he did say "about" 2 weeks.

[Arnie Madsen]

That is a great picture of your dad Stan. Thanks. I have never met him but I automatically like him because my my dad was a farmer too . A couple of years ago you showed how he was checking the new tile drains on his land. I know what tile drainage cost and everything it involves. It makes helicopters look cheap by comparison. To see someone at his age still so involved producing food for a hungry world reminds me why your country is so great. I bet he is the proudest guy in the coffee shop telling everybody about his wayward son who left the farm to build stairs and turbine helicopters.

When all the farmers look up at what is flying overhead , and when all the aviators look down at the farmland they are flying over ...... to me that is a perfectly balanced world :)

Now that you are working on your turbine fuel system I find your ideas and HobbyCAD's ideas very informative. It is a good example of things a builder has to consider.

[choppergabor]

Look at that man just how proud he is of his son's accomplishment! I love it! :) Bless his hearth he has done a great job raising a good son. He is rightfully proud. I envy all the people who have parents who can be proud of them. It must be a pretty neat feeling to make them feel that way and on a certain level earn their respect. Good for you Stan. :)

[brett s]

I would prefer a mechanical cable operated fuel valve instead that ON-OFF powered main fuel flow solenoid valve.This way you dont need to worry about auto shut downs.
The 110% RPM protection probably is ok,but you don't want an engine death due a failed low oil press sw. or false EGT indication.
I would also install an ON-OFF sw in line with the fuel start solenoid,this way you can avoid a hot start,manually disabling that valve.
Just my thoughs,hope to help.

Juan Carlos

That's exactly how I would prefer to do it :)

[StanFoster]

Juan- There is a specific swithc for the main fuel solenoid that will shut it down in a hot start condition.


I am going to talk to some Helicycle pilots that fly both ways on this main fuel solenoid switch.

Stan

[StanFoster]

Arnie and Gabor- Thanks for the comments. Dad thinks this turbine is cool. When I left the farm in 1986, he was ashamed of me...and I dont blame him. I was not the least bit interested in farming, and was independant like he is. I just had to strike out on my own...even if it was stocking shelves at K-Mart. I never had any regrets for leaving the farm, and after 3 years my dad got rid of his regrets that I had left his farming operation that was to be mine for the asking. I never asked...and I never will. It was a silver spoon operation....and that was the biggest problem I had with it. After 15 years...I had to make it totally on my own.


Today dad is riding with me to that big mansion I am finishing the railing on. I let him help me hold some patterns....kind of gets him involved in my world.


He keeps saying he doesnt know where I learned how to do curved stairways. I dont have the heart to tell him it was out of my hatred and total feeling of being a useless person while I was doing something I hated. I just had to go find myself.

[StanFoster]

It is really starting to hit me now. I kind of became numb towards thinking of flying this helicopter while I was delayed 2 weeks. That extra wait doesnt mean a thing now. One week after receiving my turbine...its sitting on the workbench trembling...and it is now waiting on me to get the clutch assembled. I will then get a cherry picker into my shop and hoist the turbine into its resting place between the frame longerons.

I was just staring at my turbine today...spinning it around on my cart on the workbench......................................... when it fell off.


Just kidding!!!!

Anyway, I know when that baby lights up the first time,,,I have a lot of emotions built up that are going to have to go. I have literally been living and breathing this build...waiting....thinking...waiting.....thinking .....and now this project is up to me to finish her. Hard telling what I will do....but I am looking forward to it. My friend John wants to fly clear out from California to share the moment when I fly it.......that means a lot to me.


Stan

[All_In]

......................................... when it fell off!

That was not funny when I read it!!!!

Now it is...

[StanFoster]

I hooked the connectors up to the start fuel solenoid...main fuel solenoid....egt, and the actuator motor.

I was leary about the fine wires coming out of my oil pressure sender...so I did the multi-layer of shrink wrap around it...and it feels secure now. I stretched one size of shrink wrap around the brass fitting...then shrunk it down...then stair stepped the others.

I am painting the oil reservoir now...and its ready to bolt on.


Stan

[dragonflyerthom]

Can we smell kerosene yet?


Looking Goooood.

Is the Jury still out about a T62 in a gyro?

I think Duane Hunn tried it didn't he?

[brett s]

Not a good choice for driving a prop, it's designed to run at a fixed (100%) rpm.

[All_In]

Stan's turbine almost all grown up!!!

I can only imagine what it must be like touching it. I love to look at the pictures, or as my grandson would say "oh it's a baby one".

[StanFoster]

John- Glad you like looking at pictures! I love just standing at my workbench turning the turbine around on its cart as I do different things to it. I have 9 curved sections of handrail that I am glueing up on my workbench the next week, that are competing for workbench real estate! Of course the turbine gets location choice. I will be assembling the over center clutch and will post pictures soon. It looks like next week I may be installing the turbine. I will miss it sitting on my bench. Stan

[Friendly]

John- Glad you like looking at pictures! I love just standing at my workbench turning the turbine around on its cart as I do different things to it. I have 9 curved sections of handrail that I am glueing up on my workbench the next week, that are competing for workbench real estate! Of course the turbine gets location choice. I will be assembling the over center clutch and will post pictures soon. It looks like next week I may be installing the turbine. I will miss it sitting on my bench. Stan

Somebody is going to get a beautiful handcrafted staircase in their home. When their guest ask "What are those unsual carving in the woodwork?" The owner is going to reply , "I am not sure but they look like miniture Turbine Engines. Very unique isn't it ?". The guest will say, "Yes , how do you suppose, they ever came up with that ideal!!:yo:

[StanFoster]

Here is the clutch apparatus assembled. It will mount in the frame ahead of the engine. The shaft coming out of that front pulley on the gearbox is the first thing that mates together when I am lifting the engine into position.

The first two picures show the over center clutch cam engaged. When its installed the rubber doughnut will compress via an electric motor powered screwdrive. It will attach to the arm pointing out to the right.

My turbine is being crowded on my workbench by a series of 9 individual handrail glueups. Move over turbine....I have to work sometime to feed you!

Closer...getting closer.....

Stan

[Flying_Lab_Rat]

Stan, I don't think you have enough bar clamps there. Need us all to get together and send you more?

-Dustin

[StanFoster]

Dustin- The amount of kind generous people on this forum, if I asked for a bunch of clamps...I would get a bunch. Thats about a 3rd of my clamps being used. I finally reached the pont where I have enough clamps! That handrail is a nasty one to bend. I made a 7/8 inch by 7/8 inch channel down the middle of it so it would mate over the existing iron balustrade. It took clamps everywhere to beat that rail into submission.

My turbine doesnt seem to mind sitting on the bench....and it makes it handy to work on.


Stan

[All_In]

I love watching and learning you build anything!
Thank you

[StanFoster]

John- Thanks. I enjoy watching all the builds on this forum. This place always has a lot of interesting builds or modifications going on. I thrive on studying others techniques so that I can add to or improve my own. .............................Riight now I am trying to paint my oil sump. I had it nice, then I put one more coat on it and I got a bump in the paint. Let it dry overnight, then sanded the bump off, and started painting again. Next my paint started wrinkling! So, I sanded all the paint off down to the gelcoat...........grrrrr.......and am trying again today between handrail glueups. Painting is one of my least understood tasks, and is my least enjoyed. .............................Once I get this oil tank painted, I will reinstall it on the turbine, and connect the oil lines to it. Then the last task while the turbine can be spun around on my workbench, is to safety wire the burner can bolts, and the canon electrical plugs. I believe I have a dual sensor that I could hook up now rather than later. Actually with the turbine installed in the open frame , there is easy access to most of its components all the way around. Plus it doesn't take much time at all to remove the engine. ............................I am getting familiar with the new designed engine mount, and it looks to me like a very well designed upgrade that only my group #5 has. I hope to have the turbine sitting in the Helicycle by nexy weekend. Stay tuned.........and thanks for the large number of hits this thread constantly and consistently receives, even when I didn't post for almost 2 months, it was receiving 1500 hits a week stagnant. I really appreciate the interest and it is a catalyst for my enthusiasm, and it keeps me on my toes more! I have listened to lots of advice, and have changed my mind several times because of it. I can now say it will be flying next month, if my checkout scheduled in August goes well. The FAA is working wit me directly, and I should be able to call Tom Milton......da man!........down to bless it with an airworthiness certificate once I have my build complete. Lots of stuff to wrap up, but its looking like a downhill run that the finish line is just starting to come into view....................I am really starting to get excited, and I can only imagine what it will feel like watching Doug Schwochert fly it the first time. Then when I get to climb in and take it for my first hover, I know it will be the most exciting experience I have ever had with a machine. I can't wait!!!! Yes I can wait! I am a marathon waiter! Stan

[animal]

John- Thanks. I enjoy watching all the builds on this forum. This place always has a lot of interesting builds or modifications going on. I thrive on studying others techniques so that I can add to or improve my own. .............................Riight now I am trying to paint my oil sump. I had it nice, then I put one more coat on it and I got a bump in the paint. Let it dry overnight, then sanded the bump off, and started painting again. Next my paint started wrinkling! So, I sanded all the paint off down to the gelcoat...........grrrrr.......and am trying again today between handrail glueups. Painting is one of my least understood tasks, and is my least enjoyed. ............................. Stan you will need to let that paint cure for a few days or it will just wrinkle again. trust me I have learned this ,the spray can paints are the worse. I was playing around with doing flames on my harley, had a nice yellow lay out done, let it dry over night ( which was not long enough ) layed out an area over the yellow to spray some orange ,and about 15 seconds after the Orange paint hit the yellow it started to wrinkle.

wait awhile before you try and go back over it,trust me it is a losing battle.

[Friendly]

It must be a treat for Tom Milton also, to inspect something as complex as a heli, while having the confidence that he has looked at the build pf each piece with great detail, thanks to this thread.

[All_In]

All great news!

I am a marathon waiter! Stan

Oh good news Stan didn't know you had taken another job?

Then Gabor and I will have a glass of non-sweet tea and a rack of ribs! :eek:


I know we are a great distanced apart but it should be no problem for a marathon waiter! :lol:

[dragonflyerthom]

Keep up the good work Stan. We are almost as good as you on the waiting thingy. Still looking Goooood.

[StanFoster]

Thank you Thom.

My oil tank is now painted successfully for the 2nd attempt. I am pointing to one of several nuts that need safety wiring. My turbine is watchng rail # 2 and rail #3 get bent and laminated on the workbench. Its time for the turbine to get off the bench and into the chopper.


The next to the last picture are the parts left to mount the turbine into the frame. The last picture is the Helicycle looking forward to receiving its new heart late next week. I will have to remove the tail rotor driveshaft, which takes about 10 minutes , so that the belts can be put over the top pulley, and the cherry picker can have easy access to carry the turbine into position.

I dont have a whole lot to do to get it mounted in place...but there is a lot of msc. hooking up...and a long punch list to go through. But the end keeps getting closer.

Stan

[StanFoster]

I think my work is trying to tell the turbine to get its finesse stuff done and get it off the workbench. I have a hard time keeping track of my hours in a day. I glue up a rail, go work on the turbine...or paint something...then back on the rails....then back on the turbine....then mow...then back on the rails....etc.


I am always looking up the exhaust at the turbine wheel....reaching in and tuning it. Its too alluring.


Stan

[kstorm32]

Stan

Do you have to wait to fire the turbine till the check out?

Ken-

[StanFoster]

Ken- I will wait till Doug Schwochert first fires it up at my checkout. There is too much I need to learn before I start it up. I waited a long time for that turbine, and I can wait for Doug to light it. I know just enough to mess it up................................................ ........By the way, I was laying out the parts for the turbine mounts, and I was extremely impressed with the nwe design they came up with. I have to say I am glad I had to wait to get the free upgrade. I will post lots of pictures showing how the turbine can now be lowered parallel to the drive pulleys. Very simple, yet well thought out. I will be posting some action install shots next week. Stan

[scottessex]

Hey Stan if you get addicted to kerosene...... here is another avenue for you to pursue.
http://www.videowired.com/watch/?id=2643065351

[StanFoster]

Here are pictures of the newest engine mount that Eagle R&D came up with. I am very impressed how simple it is to adjust, and how beefy it is. This had to take a lot of thought. Whats different about our new mounts is that it bolts directly to the turbine studs sticking out each side. I have my finger pointing to one stud in the last picture.

Whenever the belts need tightening....the engine is lowered until 35 pounds is measured on a pull scale as the overcenter clutch cam goes into lock. Then the back of the turbine needs to be lowered slightly and with the allen set screw on the right that you can see in the first shots,, and the double rod end adjustment linkage on the left side....this is the nice system that was well worth waiting for in my opinion.

I hopefully this time next week will see pictures of the turbine hanging off these brackets....and the front clutch mount.

The turbine will be very simple to take in and out of this ship as there are just a few bolts....and simple canon screw on electrical connectors.



Stan

[animal]

Looks Good Stan. very nicely designed.

enjoying seeing how this Helicopter is designed. a lot of thought has gone into it.

[choppergabor]

Looking good Stan. It sure looks simple enough, but again just how many times are you planning to take the turbine out? Hopefully not too many!

[StanFoster]

Here are pictures of the clutch mechanism being fitted to the front shaft of the turbine.

Its in the ship with the drag link and rubber shock mount installed.

It just a matter putting the turbine on a cherry picker and hoisting it into place docking with this clutch mount.

You can see I have actuated the clutch arm and the over center engagement of the clutch for this photo session.

I have to stop, think about things...then next week install the turbine. I am in no hurry....just savoring the build.


Stan

[StanFoster]

I have to have the tail rotor driveshaft removed so the cherry picker can lower the turbine from above....plus its necessary to install the 6 drive belts on the transmission pulley.

Its a very simple design..and when they say it can be removed in ten minutes...that was 5 minutes too much time.

Just follow the pictures. You remove two bolts at the rear star drive coupler...and slide the coupler out of engagment into the driveshaft.

Remove 4 carrier bearing retaining bolts, remove one bolt to swing the vertical stabilizer brace back an inch....and carefully pull the driveshaft out of its front star coupler engagement. Then carefully guide it straight back being careful not to scratch it on close objects. There...all of 5 minutes!

Part of my annual or will be to remove the driveshaft and just feel the bearings for any roughness or looseness...then reinstall it. I like the open tail design over the enclosed ones..as I can check these bearings every flight for temperature..and just look them over good.

The last picture shows a carrier bearing yoke with two 1/8 inch holes. Those holes when lined up with two 1/8 inch drift punches...exactly place the tail rotor driveshaft back into alignment. If you dig way back in the archives of this thread....you can see where I used taut fishing line to align the driveshaft. I even double checked with a laser...but in this case the fishing line was handier.

I have a few more bench operations to do on the turbine..such as safety wiring. Its a little handier doing it on the bench...and I am going to miss the turbines short stay on that little cart. This week, its going in for good into the frame.


Stan

[All_In]

Very, very exciting... It's getting close!

[StanFoster]

Last things to do before installing the turbine. I safety wired the burner can bolts...and 6 turbine bolts...

I had to make a little bracket to hold the spring that returns the fuel control valve to idle. I am thinking of having a 2nd spring for redundancy, but first will check with Doug to make sure I dont exert to much spring pressure on the linear actuator motor.

Then I filled it with oil......and put my ohmeter on the oil pressure sender, just curious to see if there is any indication of oil pressure.

I first had to add extra oil in the oil tank so as to rise above the level my finger is pointint to in the last photo. That is the oil line coming from the tank to the inlet side of the oil pump. The loop stops the oil tank from draining down below the level of that loop....but it has to be above it initially to get oil to the pump.


I put my ohmeter on the oil pressure switch...and at static ...it indicates .25 ohms. I started spinning the front pulley....and after a hefty windup....I started getting oil pressure. The ohmeter read lower the faster I spun it. I had it down to .18...but time I snapped the picture...the turbine was slowing down and I caught the .196 reading.


One last thing to do is to secure my chrome oil cap somehow. I think I will just have dual safety wires on it....and will just drill the holes for now.


Its going in this week....stay tuned!

Stan

[StanFoster]

Less than an hour I can have the turbine physically installed. I am going to do some thinking making sure there isnt something I forgot or could work on easier now than after its in. I am planning on doing this sometime Wed.

The first pictures are making sure the main transmission pulley is plumb. I have some wedges under my skids locking this in.

I have the drive belts on and tucked out of the way. The turbine mounts are marked to within 1/8 of an inch of their final position.

I have waited a long time for this moment where its ready to go into the frame....but now I want to savor the moment and just sit on it for a day or two. I love being relaxed and mellow as a tomcat. Thats the mode one should be in all the time.

Stan

[Monte55]

I love your attention to detail

[StanFoster]

Monte- Thank you. Paying attention to detail is a necessity sometimes! Stan

[Resasi]

Quality machine, quality build, quality build log.

We are all enjoying it almost as much as you are Stan.

Just love that long slow deliberate finish, savoring it to the last.

[choppergabor]

Finally a picture of your helicycle with the turbine and I didn't even have to Photoshop it into the picture :) Looking almost complete!

[StanFoster]

Gabor and Leigh- Thanks. Between handrail glueups today, I will install the electric motor clutch drive. I will need to be activating the clutch mechanism as I do the initial turbine position set. Once this is done, then I will be doing all the final wiring of the clutch , micro switches, all the finalconnections to the turbine, etc, etc. There will be plenty to keep me busy for about 2 weeks! Stan

[choppergabor]

You mean a "real" 2 weeks and not that "slogan" 2 weeks right? :)

[animal]

wow I can almost smell the kerosene. looking good Stan.

[Kandace]

I love the smell of Jet A in the morning!

Kandace

[StanFoster]

I had to modify the trunnion in the yoke of the engagement screw drive. I was in the other room happily grinding away the square corners on my disc sander....then brought back in to check for the fit. It was perfect...so I started screwing it back on the drive screw. Thats when I noticed very tiny ball bearings coming out in the grease!

I thought what the ????....and then noticed a sleeve that came out that had holes for 12 of these small ball bearings. I found ten......and my wife can tell you....when I am looking for something....everything else is put on hold. I was on the floor carefully looking for #11 and #12 ball bearing. These look like they are about a 16 inch max in diameter.

After 30 minutes I find #11 and spent another 15 minutes looking for the last one. I mean this thing could have been kicked and gone 30 feet.

I am persistant as hell....and I went into the shop where my disc sander was and carefully looked around.....and 15 minutes later ....lo and behold there that little fart was in the dust!

I went back rewarded once again for not giving up....as it usually pays off.

I am now in a quandry trying to figure out how to get these ball bearings in the sleeve and keep them there while I thread the drive screw in. I dont know the answer, but I will not give up till I find out.

Right now I have stair railings to attend to.


You can see the ball bearings in little dabs of grease that I used a small punch to position them in the sleeve. I just am going about it wrong as far as getting that screw inside the sleeve. The ball bearings ride in the thread of the screw and are contained in the spiral row of holes in the sleeve. Delicate...to say the least.


Stan

[Chuck Roberg]

Stan, I'm just amazed at your attention to detail and your patience. I'd love to see the smile on your face the first time you hover it.

Calling your labor of love "it" seems a little harsh. Have you chosen a name for your new ship?

[StanFoster]

Chuck- Yes, I have name it.....the "TURBINATOR"



I figured out the trick to getting the 12 small ball bearings all back inside the apparatus.....it took more than grease to do it. I layed on the floor working over a paper towel should one drop and they did a few times. I had to hold a penlight in my teeth...a small manuevering punch to move the little greased balls into their carrier holes...then slowly try to turn turn the screw into the carrier without sending the balls scattering. It wasnt easy...but after a few attempts...I got the hang of it. The trick was to successfully end up with all 12 balls inside...and not just 11. I must have looked like a circus sideshow....but its done and I can advise how to do it now.

There are two small bolts that thread into the white yoke.....these bolts have a turned down pin that goes into the trunnion.

Stan

[Gyro_Kai]

Haha, who doesn't know the feeling. I imagine you gave that last bearing a big hug, when you found it.

Kai.

[TansAir]

Chuck- Yes, I have name it.....the "TURBINATOR"


Stan

That's a perfect name for such an awesome machine Stan!!! Looking forward to some glorious first flight vid's. -Kevin

[StanFoster]

This is the throttle return spring which I am planning to add a second redundant spring to if its ok'd by the factory.


Meanwhile I didnt like the raw spring rubbing on the hole in my bracket even though I put a nice internal radius on the hole. I put some shrink wrap onan the two ends of the spring to seperate the metal to metal contact.


The last picture are the drive belts all tucked out of the way...just waiting for the turbine to be installed tomorrow sometime between rail glueups.

I have the electric motor engagement all wired and tested. There is a DPDT switch in the cockpit...down for disengagement...up for engagement. Plus the engagement has two speeds...the slower initial startup goes through a 10 ohm 5 watt resistor...and its nice and slow. Once the rotor starts to engage...then you go to the higher speed engagement switch.

The last two pictures show the disengaged position with the yoke to the top..and the engaged position with the yoke to the bottom. I have a red disengagment light and a green engagement light in the dash panel. These will be activated by micro switches placed at the top and bottom of this drive screws travel.
I tested all posibilites of wiring failure..and was satisfied it was good to go.

Stan


Stan

[utahgyrocop]

Stan,

As always thanks for the progress reports and photos of your beautiful build. Your an insparation to us all.

For tomorrow, you will be in our thoughts as you certainly will achieve your goal of installing the heart of your turbinator.

Keep up the good work and stay safe.

[RICK MARTIN]

I'm really starting to get excited for you Stan. It's really looking great!

[birdy]

It's really looking great!
Blood oth. :)
Itll be a shame wen you git it out ere Stan, and have it git covered in dust n cow sh!t. ;)

[RotoPlane]

Man you are getting a lot done on that turbine! Are you sure you're still working on that stairway...pardon me....circular stairway?

Oh….after much thumb pointing…I can now see that you are right about remembering throttle roll direction. ;)

[Redbaron]

they got cow **** in illinois stan? bloody hell, bird I don't think stan knows what cow **** and dust looks like! :D

It's really looking great!
Blood oth. :)
Itll be a shame wen you git it out ere Stan, and have it git covered in dust n cow sh!t. ;)

[StanFoster]

Thanks everyone for the kind comments. Its a big family here with all the projects going on and I just love watching others build threads. Just trying to pay back for so much I have learned here.

Today is the day I install the turbine into the frame. The turbine was sitting on the floor trembling a little as I carefully wove a chain around the starter and the fuel pump assembly. The idea is to have it picked up above its cg...sound familiar?

The engine mounts are awaiting their new job of holding the turbine in precise alignment.


The last picture is my clutch engagement which seemed to be hanging up a little on its upper travel of disengagement. I have to grind just a little more spherical relief on that trunnion bearing that goes in the yoke. You are supposed to be able to run the screw all the way top and bottom and still hold the buttons on without fear of hurting the motor or jamming it. It freewheels at full upper and lower travel. My upper travel was sticking a tad...and off it will come to regrind it. Now that I know there are 12 little ball bearing in there...I will be more prepared!


I have a large rail glue up this morning...then I will go get the hoist...install the turbine....and do a 2nd rail glue up later in the day....if all goes according to Hoyle.

Stan

[StanFoster]

The turbine is installed. It went as rehearsed. I worked in solitude, and easily installed it without any distractions. I have to fine tune the exact
alignment yet as far as for/aft and parallel....I just need to stop, punt, and think about it before I get all lathered up. I am in unusual turf here, and I proceed slowly until I know what I am doing.


Stan

[RotoPlane]

Outstanding Stan!!!! I was really hoping the gear wouldn't collapse ;).

[animal]

Good Job Stan! wow after all this time N360 has her engine mounted.

I bet you are really getting excited now.

man you are so close now to flying that baby that i can almost feel the rotor down wash. hope it is cooler where you are then here.

I got motivated to get out in my shop and do some things to N814S and the temps hit 102 degrees. needless to say i came back inside to the suprise that your engine is mounted.

I am so excited for you that the long wait is finely paying off.

"TURBINATOR" Stan you are cleared for take off!

[StanFoster]

I am ecstatic right now. I went back to my rail work...got it done..then just sat in my chair and figured my way of aligning these pulleys. Any of you Helicycle builders following this.....this is my way and wasnt in any of the build videos. I make a living at knowing how to align things...and I have some basic methods that work.

We all know we have to have the pulleys in line...for and aft, and parallel vertically. I made a straight edge gauge out of some wood laying around...and you can see where I notched if to clear a drag link. My initial adjustment was only 1/8 inch out of line...so I marked the frame clamps...loosened them and tapped them forward an 1/8 inch. Voila....perfect for and aft alignment. I have the top and bottom pulley faces dead vertical...so that took care of them being parallel vertically.

But next comes having the pulleys parallel laterally.

Some if you really follow along closely, so the following is for you! I dont feel this is being anal...but just wanting to know my pulleys are in exact alignment...

You can see the blue tape I have on the wall. I aligned a spot on the wall by sighting across the transmission pulley which is dead level. I aligned the left edge of this one inch wide tape to the pulley face. Stay with me here...this is important. I then ran the tape vertically...and next sighted across the lower turbine pulley that has to be in line with this tape also. HOWEVER, because of torque being applied to the rotor...I actually aligned the lower pulley to the right side of this one inch wide tape. This allows for the upper pulley to totque a little to even more exact alignment that had they been set perfectly at no load like they are now. One inch difference across 14 feet...is right at 1/3 degree that I am leading the lower pulley....anticipating torque to cause the transmission pulley to move to the front side of that tape. Even if it did not move a bit...I am still guaranteeing it to be within 1/3 of a degree of alignment. I have seen some that I know are 2 degrees off and run fine.

If you look closely at the 3rd from the last picture...you can see the face of the upper pulley in alignment with the left edge of the blue tape on the wall. The next picture shows the bottom pulley face in alignment with the right side of the tape. This tape is 14 feet away...and is one inch wide. That is 1/3 of a degree.....plenty close enough.


The last picture shows how I shimmed the turbine to the left at the rear. I placed two thin washers behind the right motor mount. I can rest assured its as good as I can get it. I love these new designed engine mounts. I would not have had near as easy of a time aligning everything. Kudos to Blake for designing this....and I hope my experience aligning mine pulleys can be used by other Helicycle pilots.

I am very satisfied that I did my best to have a very nicely aligned turbine powerplant. Its a good feeling I am going home to mow the yard with!


Stan

[Vance]

Progress is such a satisfying thing.

This is an aircraft to be proud of.

Thank you, Vance

[choppergabor]

Nice job on the alignment. That should be plenty aligned by any measure! :) Great job. That turbine looks so real it's almost like as if I didn't photoshop the thing into the frame..... :)

[Resasi]

That is going to be one show prize winning machine.

[All_In]

You deserve it buddy! You have waited and waited never giving up hope and you have worked so hard at building the fineness ride there is!!!

It is exciting!

[StanFoster]

Thanks again for all the comments. This has been a fun project.

I had to pre-set the tension on the drive belts. To do this...you simply swing out the drive screw..place a 3/16 inch bolt across the yoke....and attach a pull scales. The correct tension is to have 35 pounds of pull just as the over center mechanism kicks in. After one hour of running...it will have to be tightened slightly....then at 5 hours.....then every 25 hours there after.

This system limits the torque that can be applied to the rotor.....correct tension and it will only pull so much. If you cheat and tighten the belts up to 40-45 pounds...you will be have more power available. Just like anything...things can be adjusted beyond design. The engine can be made to produce 160 horses too....instead of 90-95.

I installed the big idler pulley...and it went in as per specs. My pile of parts is dwindling.


Stan

[StanFoster]

In case any Helicycle guys are wondering what these new engine mounts look like and what I think of them, here are some pictures.

It is very easy to adjust both sides to raise or lower the rear of the engine....to roll the engine.... yaw the engine or move it for and aft. I called the company and told them they had hit a grand slam when they made these brackets. Well thought out...and if my simple mechanical mind can work these...anybody can.

I dont see any reason why I wont be occasionally checking how parallel my pulleys are and tweaking these easily adjustable brackets.

I love the shear clamping power the main bolts have on the longerons. They arent going anywhere until you loosen them. The older style

mounts are working well...but these are considerable stronger. It was worth waiting "2 weeks" for.

Excuse my exuberance, but I am really starting to get excited about this. I had cooled off for about 2 weeks...but that is history.
Stan

[choppergabor]

That's a pretty clever way of adjusting! Wow. It was well worth the "two weeks" of wait. Imagine if you had to wait 5-6 months! Phew. Lucky puck. :)

[StanFoster]

I cant stand seeing the tail rotor driveshaft on the floor...so 5 miutes and it was back in secured. Heres the sequence.....

Align the bearing holders with two 1/8 inch punches into alignment holes....

Tighten bolts...repeat on 2nd carrier bearing...

Align star coupling....


Insert bolts.....


Tap em home with a sledge........


done....


Stan

[ylf]

You know you have the holes sized just right when a light swing of the sledge puts the bolts through, anything less is too loose.

If you can't fix it with a hammer, then you've got an electrical problem.

[All_In]

Looking great buddy!

[kstorm32]

Stan

Do you have to make cooling fins,what kind of tail pipe?


Ken-

[StanFoster]

Ken- I was told the cooling fans were not necessary on the turbine, but were carried over from the piston model. I have a chrome exhaust pipe coming, its on back order, and I was told today it should be here in about 2 weeks. Seriously. Next steps are hooking up my micro switches for the clutch engagement and disengagement lights. I have to wire up a dual hall effect sensor for the computer governor and the digital tach. These are all shielded wiring. I can see my way through to the end now. Very little head sacratching left. I have to mount the exciter, voltage regulator, run the #6 wire to the starter, plus hook up about 10 more circuits. Still lots of fun stuff yet ahead. Stan

[Lee Scatt]

Be careful mounting the exciter, it can really slow the build down.

[lanichol]

Woodworking shop and you use sledge hammers. lol

[StanFoster]

Larry- Of course the sledge driving my tail rotor driveshaft was an example of my lame humor............but.............that sledge hammer always is available when I am setting a big curved stairway into its opening, especially the 180 degree ones. The tolerances are tight, and tight means sometimes "stuck". I then take my sledge and a soft wooden block and start applying impacts to the bottom tread nosing. The soft wood spreads the many foot pounds of impact that the sledge has over more milliseconds of time. This does two things. It doesn't damage the stair tread, and it gives a powerful "push" from the impact. Guys think I am kidding when I get my sledge out to drive a curved stairway into position. A sledge and a block of wood are a perfect team for applying a push. That is why carvers use wooden mallets to drive their carving chisels. It supplies a push which is controlled easier, than a steel hammer hitting
the chisel. I am just doing the opposite putting the wood between my hammer and the tread. .........................Back to my tail rotor driveshaft bolt, I used a wood dowel to tap it through its hole. Stan

[StanFoster]

This is the dual sensor plug I have to wire up next. It will send the rpm information to the governor and the digital tach. The wiring is all shielded.


The two pictures before the last one are the clutch engaged with the arm to the bottom...and the clutch disengaged with the arm to the top. The device freewheels at both ends so you arent relying on the lights in the dash telling you when to let off the swithes. You can hold them on past the stops..and nothing happens...except the indicator lights show its either fully out of gear or fully in gear.


The last picture are the loose wiring I will slowly attach and get this thing closer to flight.


Stan

[StanFoster]

Anybody that has ever built something...knows that a lot of the little details is where all the fun and time goes to. For instance, these little brackets that hold the micro switches have to be made. It probably took about an hour to figure out what size...bend it, fit it...then another 1/2 hour going to the hardware store for some #4 screws and locknuts, and hoseclamps to mount them.

The micro switches will have little tabs coming off the yoke on the drivescrew. Those are just temporary bolts as the correct ones are being shipped.

The clamps will let these be ajustable as the belts stretch over time. It will be a simple maintenance procedure of mine to make sure the engaged and disengage lights are triggered properly by these micro switches.


Stan

[StanFoster]

I had a mental lapse when I was installing those two micro switches. After posting the pictures of them, I thought.....I need to put the switches behind the aluminum brackets........duhhhh!! I soon corrected that and will post the better improved look.


Stan

[All_In]

Man this is really getting close now!!
That's what I really like about you, You tell it like it is buddy, we would have never known.

[animal]

I am always amazed at your detailed work.

that is going to be one sweet flying helicopter.

[StanFoster]

John- My builders log shows I have right at 700 build hours as of yesterday. I am estimating no more than 30 hours left to finish up. When my turbine arrived a little over 2 weeks ago, it looked overwhelming and intimidating . I mean this thing is not "normal" to a farmboy. I had so many head scratchers to think through, and just like building a stairway, I took it one step at a time. I see nothing left to do on it that requires much new thought or study. Its down to just attaching a voltage regulator, excitor which is an ignition coil, running some starter wire, and hooking up the rest of the wiring. Its like I was finishing up a tractor for dad on the farm 30 years ago. Next month I will be flying that Helitractor over the farm. 2.5 years and I am ready! Stan

[All_In]

While reading the above I realized that I had a BIG smile and my spirit smiled with joy, I can only imagine what you feel like buddy!!!

If we are this happy for you, you must be ready to explode with joy!

[StanFoster]

John- Thanks pal. I would have to ask Vance for his literary skills if I were to describe how exciting this build has been from the start, and especially now that I am so close. I can only imagine what it will feel like when Doug first fires it up. This will then be topped and harder to explain when Doug flies it the first time. But when I get in it, start it up and carefully bring it to a hover, my way with words will butcher trying to explain it correctly. I still can't come close to explaining what a sensation it is to fly a helicopter. Stan

[StanFoster]

I worked 2 hours today on the chopper and made my exciter and voltage regulator brackets. They are painted and will hold these items neatly underneath and out of the way. Stan

[Vance]

John- I would have to ask Vance for his literary skills if I were to describe how exciting this build has been from the start, and especially now that I am so close. I can only imagine what it will feel like when Doug first fires it up. This will then be topped and harder to explain when Doug flies it the first time. But when I get in it, start it up and carefully bring it to a hover, my way with words will butcher trying to explain it correctly. I still can't come close to explaining what a sensation it is to fly a helicopter. Stan

In my opinion you communicate your feelings well.

I have been following this thread from the beginning of 2009 and I can hardly contain my excitement as the fruition of this venture draws near.

I have been with you every step of the way my friend. I have found your narrative extraordinary.

I wish I could have been more help.

Thank you for sharing the fun, Vance

[StanFoster]

Thank you Vance-------


I have the #6 battery cables run...and all spiral wrapped. I love that stuff. I do not want to trust just the rubber insulation of the #6 cable keeping 12 volts from arcing to the frame somewheres. This spiral wrap gives another thick layer...plus I can double it at any point I want.

The first pictures are of the exciter bracket I made. It serves as a nice ground point for the turbine. I have several grounds going to the turbine...transmission...governor and frame. I guess some times pilots like to be "grounded".

It looks better getting rid of my power wires. I will use some white plastic ties to finish buttoning up the powere cables to the longeron frame tube.

The last two pictures are the microswitches that I hid behind the aluminum brackets like I should have intitially. I posted them a few posts back. I was actually looking at them on the forum and hit my forehead realizing how I wasnt thinking on my initial placement.

Stan

[helipaddy]

Stan, The white cable ties UV degrade much faster than the black ones, keep an eye on them.

Been following this thread, Da Vinci would be proud of your Masterpiece. Simply superb!

Paddy

[StanFoster]

Paddy- Thanks for the comment. Thanks also for the heads up on the white ties not being as ultralight resistant....I was not aware of that. Now that I know....I will just make it part of my annual to replace the white ties. Thats a minor inconvienance....and black ties on my white longerons look hidious!! Helpful comments like yours is one big reason I post so much of my build. There are a lot of other eyes looking over my shoulder, and I appreciate a finger pointing out stuff that raises a red flag. Thanks again...and good flying on the other side of the pond to you!


Stan

[StanFoster]

Heres a picture of the governor with the box off of it. I have the exciter all connected. Its the little white box under the turbine. I have it all hooked up and I can hear the sparks popping inside when I hit the button. I am testing each system as I go.

I had to fanangle a bracket to hold the steel braided ignition wire in place. I like to button up as I go...then I can feel progress.

I am slowly chewing on the spaghetti bundle of wires.....its getting down to just hooking up one circuit at a time and testing it. So far I havent had anything miswired.


Stan

[All_In]

Man this is exciting...
Nice work!!!

[StanFoster]

John- Thanks. I have posted almost every step of this build, and I basically got committed to doing such by a good size of Helicycle lurkers that keep prodding me along by sending my e-mails and PM's thanking me for the details. I am trying to pay back a little for what I have taken off this forum over the years. This thread took on a life of its own from the very beginning and I feel grateful there is so much interest in it. I have received a lot of valuable tips along the way, and have done a few things differently because of these valuable comments posted here.

I am planning on not posting anymore in this thread after I make my first couple of flights....as I feel the Helicycle has "hatched" out...and a new thread of its future experiences will be started.

So.....I am getting ready to go out to my shop at 5:30 and spend 2 hours working on some more circuits.....which of course I will post here later.

Thanks again for all the interest.


Stan

[Resasi]

Being more of a 'flyer' than a 'builder' I will be looking forward very much to the 'Hatched' thread Stan.

I will though say how much I have enjoyed the meticulous workmanship and your craftsmanlike approach to this project. It has been a long and interesting journey since you first intrigued us all with the mystery project that you were about to embark on.

As you so rightly point out, people have learned from your progress on this thread and in turn, you profiting from contributions you may not have otherwise recieved: what goes around...:yo:

[choppergabor]

Oh yes! It looks to me as if it was already flyable even with a few wires still hanging..... :)
That's a beautiful machine Stan and you did an immaculate build on it. Almost there my friend :)

[jcarleto]

Don't look now, Stan. Someone took the letters "I" and "O" from your governor. I'd look around on the floor for 'em. It looks like a clear case of leaky vowels.

:boink:

[StanFoster]

I wired up the voltage regulator, main fuel solenoid, start fuel solenoid, exciter, actuator, and the egt. Each system checks out. My spaghetti pile of wires is almost gone.


I put a torch onto my egt probe in the exhaust and caught a blurry dash picture. I made sure I didnt peg the gauge...but it was at 1200 degrees. It cooled off a lot time I took the picture.


Stan

[All_In]

Now that's testing...
I heard the exciter over the phone today, man that is a loud spark!!!

[StanFoster]

I had an early morning session...and its past 7 and I have to get on my stairwork.

The right side is all buttoned up wiring wise. I have the spiral wrap completed past the landing gear. I had to order some more to go on into the belly of the cabin. You can see all my wiring on the longeron frame tube awaiting to be spiral wrapped. That is some good stuff.


The left side has just a few wires left to do for the dual sensors...and wiring my micro switches for the engage and disengage lights.

I am not done with the wires around the turbine.....more spiral wrap coming there too.

Other than that.....its getting close.

I can hit the start button...and she starts cranking. The exciter is sparking a lightning storm inside the burner.....just waiting for JetA to be fed to it.




Stan

[irace2win41]

Stan, that is one nice build. Learned a lot. Beautiful work and a nice ride.

Rod

[StanFoster]

Rod- Thanks for the comments. I have learned a lot also, .........and have a lot more to learn. I have been asked several times locally and here if I am going to start the turbine before the checkout. NO WAY........I know just enough to get it started, but unlike Red, I wouldn't know what to do fast enough if something wasn't right. I have run the starter up on it to around 18000 rpm, checking my oil pressure, looking for leaks, etc. It sounds sweet hearing it spool up and seein 25 pounds of oil pressure. So far all systems completed are go for launch. I am absolutely loving this final wrap up. I hit one circuit at a time and don't move on till its done and double checked. I only have the dual sensor and the clutch micro switches to finish for the wiring. Two fuel lines and she is ready to light. Stan

[choppergabor]

Good for you Stan for not destroying the fruit of you long and hard work. Let the pro check it out and as much as you are probably itching to fire that baby up it is well worth to exercise the well known "two weeks" slogan till it comes :) Your work is immaculate and you should enjoy your baby for a long time. Looking great my friend.

[irace2win41]

Stan, can hardly wait for the first flight video.......

Rod

[irace2win41]

By the way, will be going to Oshkosh for the first time in 25 years. Hope to meet some of the Rotor guys while I'm there. Man is there a lot to catch up on in aviation since I left.......

Stan that helicopter is a pure work of art!

Rod

[GrantR]

So Stan, How many times have you hit that starter button to hear it spool up? :)

[animal]

Stans going to wear out the starter before he gets to fly it..lol

yeah yeah we know, call it a test all ya want, we know ya love to hear that weir and tat tat tat as the ignitors fires..lol

[All_In]

Well it's official! Stan is a whiner!!!
Yep, I head his turbine whining over the phone! Music to my ears.

Buddy we need a youtube video just to share your new Love song with the rotorheads!

[StanFoster]

Heres a link to my whining


YouTube - July14.avi (http://www.youtube.com/watch?v=n-V7COPK_oE)


Stan

[Chuck Roberg]

All whining aside. I'm really happy for you.

[asmuzsr]

heres a link to my whining


youtube - july14.avi (http://www.youtube.com/watch?v=n-v7copk_oe)


stan
it's alive!!!!!!!!!!!!!!

[choppergabor]

Love it Stan!!!!!!!!!!!!! Sweet sweet sound. I almost heard the igniter do it's thingy and the deep humm........

[Lspav8r]

That was KOOL. And is that your garage. I can't even find the floor in mine. Man that is clean.

[RICK MARTIN]

That's what I'm talkin' about! That's the sound that says "Yea...........I'm for real!

Whoopeeee!

Awesome Stan. Thanks for the video.

[StanFoster]

Glad you guys like the sound. I think I am addicted to this machine.........I can only imagine what it will sound like when I turn on the JetA to it...............Jim, that floor may be clean, but the stairshop through that door isn't! I had to have one area that was clean for my toy. I have a curved stairway I am about to start. That will help pay for my heli-habit. Stan

[StanFoster]

I have my dual sensor hooked up now, and I just finished making brackets that trigger the engage and disengage micro switches.

The clutch automatically freewheels when its either fully engaged or disengaged....the lights in the panel tell me when to let off the buttons.

I have to spiral wrap the wires....then this is done.

Stan

[Kandace]

Hi Stan! That is wonderful. I can't wait to hear that you've flown it!

Kandace

[PR_Arecibo_DC]

Well Stan... Indisputable.... Is the best build I seen so far... Now the question is... When the countdown begins for the first lift-off.... Cant wait to see it in the air...

Enjoy it....

Jose

[Aviomania]

Very Nice Stan!!!! I just love that sound!!! Hope you are up flying soon!!!

[birdy]

Bloodyell Stan, ark er up mate.

That sound definatly makes the blood rush dont it?

[StanFoster]

At the risk of sounding like a broken record........thanks everyone for the comments. This chopper is almost ready for 'da man', Tom Milton to come down and do the airworthiness inspection. If it passes, then I am down to requesting a factory checklist to see if all is in order for Doug Schwocherts 4 day intensive factory checkout, and its first flight.................Everything I have done wil be scrutinized, adjusted etc. The main and tail rotors will be static balanced, then the turbine will be first started and adjusted. The main rotor will be electronically balanced very precisely, as well as the tail rotor. The cg will be adjusted, then Doug will first fly my baby to further adjust the settings of trim etc. Then It will be my turn as I take flight in my own helicopter, tbe TURBINATOR, as I fulfill a 30 year goal of mine of flying my own helicopter that I had built. I don't take this lightly, as its the biggest 'material' goal I have ever set for myself. I am excited to say the least. I am almost there. Stan

[NoWingsAttached]

Still waiting.....but now closer

[StanFoster]

I static balanced the main rotor this morning. Basically, the rotor tips are supposed to measure the same off the floor when balanced.

First order of business is to get the chordwise balance set. This involves removing the pitch links...and placing an airfoil template /level on the rotor blade. You adjust the drag link in and out so that the rotors chordline balances out to level. You kind of shake the mast slightly, and the blade will roll to its balance point. The drag link adjusts the mass of the rotor blade down its longitudinal roll axis...and its easy to make the blades nose go up or down by just very slight movements of the drag link. Once this is done...then the measurement from the floor to the same point on each blade tip should be the same.

However....I thought...what happens if the floor isnt level? Concrete especially. I checked mine and where I measured the rotor at 12 o'clock, the floor was 3/8 of an inch lower than at the rear at 6 o'clock. I checked this with a very accurate laser level. I then placed some 3/8 thick material on the floor at 12 o'clock, so that this then is a level base to start measuring from.

My inititial measurement showed the front blade was 79 3/16 inches...the opposite blade was 79 11/16 inches. I took the tip weight off the low blade and ground about a 1/32 of an inch off.

I made sure each time the the chord was level...and after the rotor blade found its own level...I checked it. It was now 79 3/8 in the front...and 79 1/2 at the rear. I was getting close.

I repeated this three times..before I ground any more. It came back within a 1/32 of an inch everytime. Next I took the wood end plug to the grinder and ground off a tad..replaced it...and I overshot a little. My low blade at the front was now 1/16 inch higher...so I ground just a smidgeon off the rear blades tip block...and checked it. It was dead on...and stayed consistently within a 1/16 of an inch for and aft off the floor measures. That seemed awfully close to me. That AN3 washer in my hand lowers the level blades 1/4 inch...making a difference of 1/2 inch. Thats how fine and low friction those needle bearing are in the hub.

I am satisfied I have static balanced the rotor blade to the best of my ability....especically taking into consideration the error in my concrete floor. That was step #1 in my opinion....making sure I am measuring off something that is dead nuts level. I mean.....why do this finesse work half hazard? It would just be a waste of time.


Next I have to pre-load the pitch horns with 3 pound weights and adjust the drag links ...and then it will be set for its initial spinup.

Doug Schwochert will be rechecking all my work....but I want to have the confidence knowing I know how to set this stuff up. I will have to hold my own hand eventually, so I may as well start now.

Stan


Stan

[Flying_Lab_Rat]

Ok Stan, now that you're nearing the end, just don't go rogue on us....must wait for Tom and Doug first before you light that candle! Almost there, hang in there! Thanks again for documenting this build so well; it will inspire may to come, and teach them to accept nothing less than the best workmanship in their builds.

-Dustin

"The Flying Lab Rat"

[StanFoster]

Dustin- I am confused. I havent even for a fleeting moment considered starting this engine...let alone go fly it! I have already stated that Tom Milton is doing the airworthiness...and Doug the checkout...........then.......it will be my turn to fly. I am not going to pull a Red Baron maneuver and thumb my nose at more experienced people. ha


Stan

[choppergabor]

I can assure anyone out there wondering about Stan.... He has more self disciple than most people. That would be the last thing he'd do. Not because he couldn't pull it off. It's just not him doing that kind of stuff. Good for you Stan. There is a rather sweet fruit of that work and patience. :)

[scottessex]

Stan why not make a water level? Take some clear vinyl tubing (cheap stuff from hardware store) and lay it on the floor, and tape it to a jack stand or something at each blade tip, so the ends come up 90 degrees and point towards the ceiling, then fill with colored water, the water will be exactly the same height at each end, regardless of the inaccuracies of the floor.

[animal]

looking good Stan, I lucked out, I just recently met a Helicopter owner in Va. that has a Chadwick balancer.

I have talked to him about helping me get the Commuter dialed in.

now to see how much he is going to charge me, but hey at least we found a Chadwick to use.

Can't wait to see the test flight of your baby.

[Flying_Lab_Rat]

I'm not doubting you Stan, and I'm not saying you will, but as we've all seen, good people do go feral at times, I'm just helping keep that little devil off your shoulder and out of your ear. I see it with my soldiers all the time. Shoot, the Lord knows I'd be tempted myself.

[StanFoster]

Scott- I would use a water level...and have years ago...but I have a very nice self leveling laser that is very accurate. Plus you dont have to allow for the miniscus in the water lever vial.

This is only static balancing. It will be dynamically balanced with an electronic balancer. I just am getting 98% of it right now. There will be very fine adjustments as the balancer indicates it is needed. I want my main and tail rotor smooth as possible.

Stan

[StanFoster]

I have almost everything done on my Helicycle. I am going to Homer Bells fly-in tomorrow to meet with Blake and Doug and go over last minute stuff before the factory checkout. I have one issue that has me stumped. My engine tach is not indicating rpm's. I have doube checked my wiring, even by passed the wiring with a jumper, switched sensors. I am bringing my tach wit me tomorrow. I have jumpers all ready made up so we can test the tach. I have to get this resolved. It has to be the tach in my opinion. My chopper will have air under its skids in August, and I don't mean by a hoist! Stan

[choppergabor]

Cool! Yeah it sounds like the tach isn't working properly. If a direct jump didn't move it it's probably pooped out. Happy to hear the progress :) Take lots of pictures Stan.

[All_In]

Next year you will be flying in yourself, how cool will that be!!!

[jcarleto]

Stan,

This is the point where most folks wish you, "Good Luck." Up to now, it has all been skill, work and effort. I wish you great skill. May you have made most of your own good luck.

I will hold out 10% for pure, dumb, incomprehensible luck though and wish you that for all your flying. You should always be at least a little lucky to make up for that 10% where skill is on a break.

There are, after all, no "highly skilled" lotto winners.

[StanFoster]

I had an excellent time at Homer Bells. Lots of Helicycles there and every one of them were having a ball flying them. Those machines are just plain tough ol workhorses. Mark Whistler who has more hours on a Helicycle than anyone showed me a 6 dollar rodend that he had to replace after 600 flight hours. That's the only part that has shown some wear. Everyone else had similar very little maintenance stories. After building one, I believe I will have the same testimony. Time will tell! After seeing every Helicycle flying today and very little Rotorway activity, it was hands down mostly a Helicycle day. They were also by far the quietist chopper flying, just a faint whistle of the turbine which I wish were louder. ............I had my tach diagnosed, and it seems its just programmed wrong. They are taking care of it.........Doug Schwochert won't be able to do my checkout till the end of August, which is ok to me. I have a few more ideas to piddle with, and after seeing all the fun these guys were having, I am just going to savor their flying until I am flying. The end of August isn't far off at all. Stan

[Rick Whittridge]

Stan, Will you be at Homers Sat 24th. I might ride down.

[StanFoster]

Rick- As much as I wanted to be at Homers also on Saturday, I also have some stuff to do on my Helicycle. I have a checklist to work on that has to be completed before the 4 day checkout begins. This thorough checkout procedure impresses me with how committed the company is to their product. I had some good chats with Doug Schwochert at Homers yesterday. That guy is the reason there are turbines in the Helicycle. My work on my chopper could not be scrutinized more thoroughly by anyone else, in my opinion. I am looking forward to an intense checkout and learning both what I did correctly as well as incorrectly. After hanging around with the Helicycle guys again yesterday, I know I have a lot to learn, but have no doubt I will learn a lot as I begin my helicopter adventures. Rick, see you at Mentone soon. Stan

[StanFoster]

After talking with Doug yesterday, I found out I could go ahead and install my 12 ounce tip weights, and locktite the screws. I asked him about bonding them, and he said it wasnt necessary, but if I wanted to...go ahead because we wont be taking them out. Thats all I needed to hear. I bonded them in this morning and locktited the screws...so them babies are in to stay.:yo:

He also wanted me to drill 1.5 inch deep holes...and drill and tap them for a 1/4 x 20 thread. He will place whatever lead is needed in one of these holes..followed by a screw that will be locktited in. The screw can be ground for final balance.


Stan

[scottessex]

Why don't you take some time and clean up that shop! Dang Stan.

Just kidding, I love clean shops, just hard to keep clean when you have too much stuff.
Looking good, very good, won't be long now, I almost hate to see the build thread end.

[StanFoster]

Scott- In all seriousness, its a pig pen right now. I want to mop the floors and straighten up the mess on my the tool box. I am embarassed at the chaos in there. My stairshop is another thing. It will always be dusty,and I dont have time to detail it except with a push broom.:D

[StanFoster]

I was talking to one of the Helicycle veterans about my charging system. He showed me his KeyWest voltage regulator and told me to change mine to that. It will run the governor and fuel control valve without any batteries at all. I told him I already have that same one installed, and that it came with the kit. I found out later that Frank had told the factory about his regulator, they listened...they tested..and they supplied.

I was pleased to also find out that the factory will modify my main fuel solenoid to fail safe....meaning if I lose power to it...it will fail open, allowing fuel to continue on. They even have a small backup battery that is charged through the sysem, but should I have an electrical failure, the fuel valve will fail open....but this backup battery will feed the governor and take care of an overspeed should it occur. The kit will have diodes that protect this backup system should stuff on the other side of the diodes short out and completely fry. I think its a good modification, and I plan to do it after my checkout.

Here are some last minute stuff I am doing now. I was told I could button up the belly of my cabin, and now I am finishing my spiral wrapping, and running my pitot and static lines.

The top instrument panel just flops out for easy access. I gauged the length of my pitot and static lines so that they would be long enough to pull the panel as in the picture. 10 seconds and the panels back in its place waiting for its screws. Very, very easy to work on.

The last picture is the latest greates potentiometer that controls the turbine speed from 45,000 to 62,000 rpm.

Its wired into my throttle grip on the collective. This throttle has a nice friction control on it as well as the collective lever also.

Stan

[StanFoster]

My Helicycle is sitting here trembling .....knowing Tom Milton will soon inspect him, and hopefully grant him his FAA airworthiness certificate he needs to become airborn. Its been since mid Febuary of 2008 building this thing....732 hours to date....all compressed it would have been built in 10 months...but 2.5 years gave me 20 extra months to think about it. In hindsight...I wouldnt have had it any other way....except for the last 2 week wait on my turbine!

I am waiting on my engine tach to get recalibrated, my exhaust pipe is being chromed right now....and the front lower windshield is removed for Doug to check my control pedals.

I still havee till the end of August at the earliest to have the factory checkout done....so that gives me some more finesse time. I am going over everything...and occasionally neatening up stuff. I still have the belly of the cabin to button up...but I want to leave that open checking all my internal wiring...controls...fuel system, etc.

There wont be many more posts until the checkout....and once I post Dougs first flight and my first flight, I will move on from this thread and free up some bandwidth!

Thanks everyone for the constant PM's, e-mails, and phone calls that keep encouraging me to keep posting in this thread. I am amazed at the number of lurkers that contact me that never post. Its a very steady stream of comments, questions...and critiques, etc. I love them all.

Stan

[Rick Whittridge]

Looking Good Stan! What A Beautiful Machine! Since you are waiting on your inspection now would be a good time to build a long Trophy Shelf on the wall of your shop cause your going to need it soon!

[RICK MARTIN]

Man oh man! What a big beautiful bundle of energy sitting there ready to explode!

Just looking at it makes me remember the post with the clip of the starter spooling the engine up.

Wow Stan. Awesome!

[StanFoster]

Rick W. And Rick M. Thanks for the comments. Coming from two craftsman means even more. Both of you do immaculate work and this forum has gained from your examples of very nice work. I have enjoyed this build more than I realized, and I am looking forward to building a Genesis later this year. Stan

[Laurent1702]

Hi Stan,

It looks that the hardest part of the job is now behind you, congratulations!

I'm wondering one thing, where is the equilibrium point of the helicopter while standing on the ground without the pilot sat inside?

Did you already try to find it with a piece of wood (broom stick) placed under the skids, wheels removed?
I'd be interested, just to see how different it could be in comparison with a R-22.

I'm still stuck very far away from home...the shipping of my Helicycle is then postponed until the end of August, or within "two weeks"! ;-)

Laurent

[choppergabor]

Wow you are so close Stan. Looking great and I know it's built well. I expect noting less than a problem free check on it and ready to fly in a very short time. Not even Two weeks time :)
Happy for ya big guy. I can feel the excitement :)

[StanFoster]

Gabor- Thank you sir. It is very interesting watching your creation come to life. That is going to be one unique gyro! Laurent- I was tickled that my Helicycle thread played a part in you buying one yourself. I will be doing a hangtest and adjusting my battery location until my mast I tilted 3 degrees forward. I will then see where my ship with me in it balances on the skids so I can have a reference point to go by with future changes in my helicopter. You will be extremely pleased with the quality of their workmanship, you will be pleased with how assessible they are for questions and Blakes excellent knowledge and pleasant personality, you will not be pleased with shipments being on time, you will eventually get all your shipments and you will be pleased with looking back at your project and saying the quality was worth waiting for...........................By the way, I received my maintenance program fully approved and signed by the FAA.

[Resasi]

Stan this thread has a large number of followers who I am sure, while being extremely happy for you when your creation takes to the air, will be slightly sad that the pleasure you have given them in the build is now over.

Well all good things come to an end, and it has been most interesting watching such high quality workmanship bring such a beautiful machine slowly to life. Looking forward to your flying exploits now.

As you say, it does seem to be just sitting there, quivering to be in the element it was designed to be in. Interesting that your machine is a 'he', I have always thought of every machine I have flown as being a 'she'.

[StanFoster]

Leigh and others- Thanks again for the comments. I have enjoyed this build so much. I never will forget the empty feeling my stairshop had when I moved my SparrowHawk out, and that was only after a 5 month build. This chopper would feel much worse leaving since its been hatching for 2.5 years. But, it fortunately is not leaving but will get to stay since its hatching place will also be its nest. I am not done building, as I am looking forward starting on a Genesis build later this year. I will probably do a thread on it....ha. I breath and eat others build threads, and am just trying to pay back to this forum all the stuff I learn from others. This forum has such a diversified cross section of very talented people. Stan

[animal]

Stan this thread has a large number of followers who I am sure, while being extremely happy for you when your creation takes to the air, will be slightly sad that the pleasure you have given them in the build is now over.

Are you kidding me, once Stan is set free in that bird, we will get to enjoy pics from his flight to places yet explored.

I remember all the great flight posts when he was flying his RAF-2000 and later his sparrow hawk.

trust me , We will have some great story's to read of Stan's new adventures in his Helicycle. just wait until he mounts a video camera on that baby.

I can't wait.

[Gary_in_Orygun]

Gee Stan,

Since you loved building that machine so much, maybe you should sell it to me and get another one so you can spend the next 2.5 years building it.

;) Ya, right!

[Gyropilot007]

Stan:

Quick question...what is a Genesis?

Bob

[StanFoster]

Bob- A Genesis is a gyroplane kit made by Nicolas. His company is at www.aviomania.com. How is your rebuild coming along? You sure can build a nice gyro. Can't wait to see you back in the air. Stan

[lanichol]

Have you fueled to check leaks, or if it will pump, ignite and shut off. lol

[StanFoster]

Larry- I have had it full of kerosene for 6 months. It is leak free. I have had my oil pressure up to 25 pounds by running the starter and so far so good. You might recall ealier in my build, I filled my tanks with water and everything was fine for 2 months. Then one day I noticed a little bit of water on the floor. I assumed it was one of my tank bolts that have an O-ring for sealing. It was my top tank, but strangely was leaking even when I lowered the water level below the suspected bolt. It was a major job removing that tank and would have really been a major job had it started leaking just now. I had a freak spot in my tank that a bulging frame weld was working on. I sent the tank to the factory and they immediately gave me a new tank. They had never had a tank leak like that. I was just so happy that even though it was a pain to fix then, it would have been 5 times the work now. I also filed down the welds where the tanks rode against and am content it was just a freak incident. Stan

[lanichol]

You might recall ealier in my build, I filled my tanks with water and everything was fine for 2 months. Then one day I noticed a little bit of water on the floor.

Oh Stan, I remember the whole process distinctly! It make me hickup when think about fixing a leaky fuel tank and grinding the inside through a hole. The RAF tank plumbing has bothered me ever since.

I was curious if you had fired the kerocene for a few seconds. Tough to resists I would think.

[StanFoster]

Larry- I have run the starter several times, and all I would have to do is hit the start/fuel button, and it would light off. I know enough about starting this turbine without the governor being set, and the overspeed system calibrated, that this keeps my finger off that button. I have too much time and money invested in this machine to risk damaging the turbine. I just have to remain patient a little while longer. During my factory checkout, Doug Schwochert will drill me on the do's and don't's operating this turbine. I feel if I get impatient now after 2.5 years and go and start my turbine, then I probably deserve to have it damaged doing so. If I have an obsession, its having an obsession with patience. Waiting for 6 months on that turbine to arrive almost found my limits however! Stan

[StanFoster]

Note- This post will seem boring to everyone except some Helicycle builders who have asked me questions that I am trying to cover here in one place.

So at the threat of being bored.....read at your own risk. :D

I am trying to minimize the chances of my turbine going silent because of fuel delivery...or my electrical system failing. I have recently been asked by e-mail and I responded I would answer it here...as other Helicycle guys will see it.

My fuel system has a few modifications to it that like any rotorcraft, are unique to itself.

My fuel is delivered out of a port about 1.5 inches above the wedge shaped bottom of both the left and right tank. I am a nut about sumps, so here was an opportunity to have a sump for each outlet. I installed a fitting at the bottom of each sump and installed a petccock for drainage. I can actually dump in a half pint of water in each tank, and it will go down to these wedge shaped sumps where they can be drained, along with any debris.

The main fuel outlets also have drain petcocks on them, and the fuel goes on to a shutoff valve, then on to a gascolator. The gascolator has a 70 micron filter, and has a metal bowl that screws off for dumping the fuel and cleaning the screen. I installed the shutoff valve ahead of this gascolator so that I could service it without dumping fuel everywhere. The valve is safety wired of course.

The gascolator has a port where I can insert a probe from my sample cup and draw fuel out...checking for water.

After the gascolator...the fuel goes to the electric boost pump. This pump is not needed after the turbine starts as the mechanical pump takes over. This electric boost pump is a flow through type so that the mechanical pump can draw fuel through it with it turned off. Some guys leave this boost pump on, and some dont. I will leave mine on. I like the idea of constant fuel pressure keeping the mechanical fuel pump primed under pressure.

The fuel leaves the boost pump and goes to a fuel control valve...which from the cabin I can shut it off....send it to the turbine...or turn it to aux and fill the aux tank on the ground either by gravity feed, or by pumping it in. The aux tank is just a transfer tank...it holds 5 gallons...and I will use it to top off the main tanks after 10 minutes of flight. The transfer takes about 12 minutes...and it basically will top off the aft fuel tank. I have an in cabin sight tube to monitor so that I know I am not over filling this tank! This burning off the aft fuel while transferring the aux fuel minimizes the cg shift, rather than burning off 5 gallons first, then tranferring the 5 gallons from the aux tank. I did a weight and balance on it and came up with only a 7/16 inch cg shift transferring the fuel after about 2 gallons has been burned off.

Its too complicated to explain here without a drawing..but most that run this aux tank have it all plumbed in with the other tanks. The problem with that is the top tank burns off first...and its aft of the rotorshaft, while this aux tank is in front of it. The standard way sees all of this aft fuel being completely burned off first, thus causing the forward aux fuel to have its full weight effecting the cg. It will cause a cg shift around 7/8 of an inch if memory serves me correctly.

The fuel ends up running through a final 25 micron filter just before entering the mechanical fuel pump on the turbine.

I have checked the flow rates of my boost pump....both pumping and free flow, and the flow rates through my filters. All comfortably exceed the fuel consumption of the turbine by 2 to 1.

On to my electrical system:

I have a Keywest regulator that will continue to supply power to the governor and main fuel solenoid, and basic electrical needs, should I completely lose all battery voltage.


The fuel goes through a main fuel solenoid that automatically closes if the 12 volts is lost to it. I am going to convert it after the factory checkout to a fail safe mode...where it takes voltage to shut the fuel off...instead of turning the fuel on. There has to be a way for the overspeed circuitry to intervene and supply voltage to the main fuel solenoid should an overspeed occur.

The factory is going to offer a modification that not only makes the main fuel solenoid fail safe....but also have a small backup battery that will be charged by the system, but if the electrical system fails, this back up battery is diode protected from losing its voltage to the failed system, yet supply voltage to keep the governor and the main fuel solenoid open. They wont be offering this until after my checkout as they are still working on this kit upgrade.

One cant cover every scenario.. but I feel this covers the basics and is better than the stock setup. Again,,,this mod is by the factory so they are behind this change.


Stan

[StanFoster]

I am down to cleaning up msc. issues. My engine tach has failed to work...I took it to Homer Bells fly-in where Blake checked it out...and he wasnt sure....so he took it back to Idaho and verified it was fine. He suggested that I move the sensor within 0.03 inches of the pickups. I was too cautious as I could feel the magnets tugging on the sensor as I was turning the turbine wheel with my finger. I didnt want any rubbing going on. Anyway...its reading fine now. I put some little labels on my clutch switches.

You can see the starter ran it to 11064 rpm....it was way over 12000, and you can see the oil pressure gauge reading 25 pounds.


Stan

[choppergabor]

As always ..... immaculate.
I could use the craftsmanship you display....
Looking good Stan. Now you just need to scuff the paint off the bottom of the skids damn it :) (by the normal wear and tear method of course)

[animal]

Thats Cool Stan, I did not know it had a Digital tach on it.

[Chopper Reid]

Your attention to detail Stan is incredible and your machine will be the most imaculate helicopter !!!
This helicopter build is just the greatest and thanks for sharing this with us all.

I recently had and took the oppertunity of having a fly of a R22 and it was a magic expereince that I have waited many years for. Thankfully I had read a lot about flying a R22 so I was well prepared. I'm pleased to say that I was able to hover on the 3 rd go and able to land /takeoff do a couple of quick circuits etc.
I'm sure you are going to have many happy hours flying your machine Stan.

[laflyboy]

Hi Stan, your helicycle is looking great. I wanted to ask you where you got the nice throttle grip, and did it fit easily on the collective shaft. I also wanted to know what type of fittings you used for the fuel line conections at the bottom of the 2 side tanks and how did you install them.

[animal]

Hi Stan, your helicycle is looking great. I wanted to ask you where you got the nice throttle grip, and did it fit easily on the collective shaft. I also wanted to know what type of fittings you used for the fuel line conections at the bottom of the 2 side tanks and how did you install them.
the Throttle grip is for a Harley. not sure how far back it is,but Stan tells about it in the build thread.

if you spend many hours reading stan's Build, you will see he tells in detail and with pics every step of the way.

This has got to be the most detailed Helicycle builders thread to ever be written.

Thanks Stan for setting the Standard for others to follow.

[ylf]

I see you have the "Up - Down" switch installed. A very important part on any helicopter. :)