View Full Version : Wayne's Hybrid Subaru Bensen Rebuild
09-11-2008, 06:27 AM
Wayne Stargell sent me this picture last evening to post of his machine. It is a Bensen-like gyro with Hughes rotors and a Subaru engine. He has nearly completed his rebuild. The machine will begin to make appearances, including this weekend's Fort Payne, Alabama air show.
Congratulations, Wayne. I know it was a lot of work.
09-11-2008, 06:57 AM
Right on Wayne! I will be intrested to hear more about your progress as you go.
09-11-2008, 06:58 AM
Yeah Wayne's has given me some pointer on the EA-82 also,and had sent me some good close up pics of his Engine.
he said the Hughes blades fly well and the EA-82 is cheap on gas.
will be cool to see him flying it again.
good luck wayne, keep us posted.
09-11-2008, 06:39 PM
As you all know,,, Wayne has done alot of parts on my rebuild, i know his is right.......congrats BIG WAYNE....:first:
09-12-2008, 05:51 AM
Wayne sent me this update yesterday. He has done additional work on the tail. Notice the horizontal stabilizer raised into the prop-wash.
09-12-2008, 07:48 PM
looking good,,,,,,,, when you going to fly it Wayne????
09-12-2008, 08:18 PM
still lot of work yet, redo the brakes,make braces for the tail.the lights,rudder cable.about a week befor i can fly it, thanks jon for the post an allthe replys,i hope it gives other somthing think about but it not much it will fly an that what count,an have fun with it.billy can't wait to see your fly or crow hops have fun.wayne thanks for the support from you'll.
09-16-2008, 05:53 AM
Wayne sent me this picture last night. I think he's down to the last few fiddly-bits. There is talk of a pending hang test Thursday evening at 4A4.
09-16-2008, 07:20 PM
Wayne is chompping at the bit right about NOW....
09-19-2008, 06:06 AM
Wayne came over to my hangar last evening and we did the hang test. 2 degrees on the mast. The "target" for his setup was 0-4 on the mast. He spent some time on control setup and assembling the Hughes rotors. All that remains is mounting the rotors and adjusting one seat brace.
I took some detailed pictures, but left my camera in the hangar due to a senior moment upon departure. They will be posted by the weekend after I retrieve my camera.
10-05-2008, 04:16 PM
Here are some pictures from the day we did the hang test:
10-05-2008, 04:19 PM
More from the hang test:
10-05-2008, 04:22 PM
The aluminum material used in the HS is a waffle core used in race car firewalls. It is remarkably strong and light.
This is a toyota starter. Wayne has an electric "soft-start" setup that works well and typically gets 150 RRPM on pre-rotation.
10-05-2008, 05:01 PM
10-05-2008, 05:14 PM
This is video of Wayne's trial of Hughes rotors. He had previously flown with Hughes blades, but this set had a significant twist (leading edge up at end). This video is a record of testing with different pitch settings. Unfortunately, despited multiple settings and tests, these Hughes rotors could not be set in a position to create enough lift to fly.
During points in the video one hears a very rough-running engine. That is the fuel truck, not Wayne's Subaru engine. I have no idea why, but it seems that the fuel truck is frequently the loudest and worst running engine at a given airport.
10-05-2008, 08:47 PM
here we go again, i cant view the vid ! can you send it to my e-mail like last time ? thanks Jon.
Big Wayne is hard at it... it wont be long now !!!
thanks Jon for posting for Wayne for all to see.:rapture:
10-05-2008, 09:04 PM
Cool Video, his engine sounds great, to bad the blades did not work out.
10-06-2008, 01:21 PM
thanks jon,can't see video.looking good.wayne.
10-06-2008, 02:22 PM
They are spinning fast but no lift. Maybe needs more pitch.
I hear the price is good on them.
10-08-2008, 06:11 PM
Wayne it looks like it wont's to fly,,, maybe you should think on another set of blades, i bet you could find some good used blades here on the forum.
someone should maybe get you to make some parts for trade on a good set of blades !!!:peace:
10-11-2008, 03:46 PM
Hello to both Wayne331 and jcarleto....
"JC"...you were correct...my machine is nearly a twin to waynes...however his is functional (lol).
Wayne...nice work on that...may need to ask you for assistance in the future with mine, since I too have a Subaru setup like yours.
I like the HS mods on that rudder assembly...great idea that is.
"JC" thank you for ALL the great photos...very inspirational to me (since I'm at the begining of that long road to rebuilding).
Hope you can get her airborne soon Wayne...nothing succeeds like success.
10-11-2008, 10:06 PM
thanks mike,if i can help with your gyro just let know.in time,about two weeks i'll should have it flying.wayne thanks.
10-12-2008, 10:32 AM
Wayne, I have been flying an 82 for hundreds of hours, no problems so far, although my engine turns slower because it is direct drive.
10-12-2008, 11:16 AM
james i like the ea82,i had direct drive.went to a redrive,works real good.but problem is the blades.too much twist out on the tips.can't get no r.p.m.s out of it.thanks,jon did will on the vido,jon an lewis help a lot.wayne.
10-15-2008, 08:40 AM
Wayne sent me this picture to post of another set of Hughes rotor blades he is setting up to try. I understand he is making some straps for them to connect to his current hub assembly.
These blades have no factory twist and are more similar to the blades he last flew on the gyro. I suppose we'll have to start calling Wayne, "The Man With One Red Blade."
10-15-2008, 08:59 AM
Why does the Subaru engine turn slower being direct drive?
10-15-2008, 10:15 AM
Why does the Subaru engine turn slower being direct drive?
It works like this....You can only turn a prop so fast before the tips go supersonic. The disruption in the airflow from "sonic booms" at the prop tips makes the prop ineffective for pushing air.
So, that's the limiting factor. For most props in the gyro size range, around 3500 rpm is as fast as you ever want the prop to go...slower for larger props, of course. Someone here should have the math for prop length and maximum effective rpm worked out in a table, I'd bet.
OK...so direct drive...prop can only go 3500 rpm....that means engine must be limited to 3500 rpm in that they are connected directly.
Enter the re-drive. We know that most auto engines (and 2 strokes) don't generate their full potential horsepower at 3500 rpm. Most Soobs, for example, do their best somewhere around 5000 rpm. If you want to use that horsepower, the method is to use a reduction mechanism so that 5000 engine rpm results in 3500 rpm at the prop. That way, you get maximum horsepower from the engine and don't over-spin the prop.
I hope that helps.
10-15-2008, 10:56 AM
Thanks JC. I new there was some point where the tip speed would just cavitate. I was thinking more like 4000 RPM's. I guess I need to see my ratio on my redrive to see where I am at. I do no the engine will turn 5000 RPM's wide open. Now to see what the prop is turning. Harry
10-15-2008, 11:37 AM
It may be closer to 3000 rpm on a large prop when a problem occurs. That is why most aircraft engines are designed with a direct-drive cruise rpm at or around 2500 rpm.
10-15-2008, 06:54 PM
Why doesn't Wayne try some gyrocopter rotorblades?
10-16-2008, 09:15 PM
hay tim,just weighting for my ship to come in,they said that i would be at the airport.you know some that has some good used blads let me know,thanks wayne.25 feet.
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