Finally... got my cluster plates done!!

[KDOG]

Only took four tries but now they are on, everything is perfectly square and its unbelievable how tight and solid the airframe is. I made my cluster plates 2.5" wide for 2 reasons. I wanted a little more "meat" on either side of the bolt holes and to compensate for the slight "homebuilder" imperfections. ;) And I still have plenty of room for the main gear airframe brackets and the end of the keel. Anyway, the ship is together, looks good, and again its awesome how rock solid it is. I was truly amazed. There is no slop or looseness in the slightest. Testament to a good design. I emailed Ralph a pic of my frame to put in his "In Progress" section on his site, I guess he'll get around to it when he gets a chance. Anyway, I just thought I'd share that with you guys. I'll be breaking her down again sometime soon to do some finishing work...

[scottessex]

Makes you feel good when it all fits together like advertised.
Sometimes it is slow going, but hang in there! Congrats!

[KDOG]

I can't wait to get the next set of parts in. I believe I will be getting the angle and tubing next. WOOHOO!!!

[Brian Jackson]

Kevin, and all,

I just got my first paycheck from my new job today, and the joy I feel right now knowing that tomorrow I'm ordering materials for a flying machine is almost overwhelming. It boils down to a childlike mentality, but with the soundness of mind to make the intelligent choices needed in a project of this nature and caliber.

I'd anticipated being a few days behind you, Kevin, in construction, which turned out to be measured in weeks. But we should still compare notes. I consider a Bee project every bit as much an excersise in learning and following directions as it is learning the tools of the trade. It boggles the brain to contemplate how Bensen-Era builders shared info without the aid of forums like this. Even the best-lofted plans leave room for question. It's simply the nature of experimental aviation.

Thank you to all whom have taken the time to answer my dumb questions, or simply to encourage. I believe the support and friendship I've found here has been instrumental in both my personal and "building" life. It's been a focal point for me to aim for instead of simply giving up. Keeping a dream alive is what life's about... or why bother. I cannot imagine an existance where the simple securing of food supercedes all other interests. Yet that's how I lived for the past 2 years. It wasn't that I was too proud to ask for help...

In astuteness,
Brian Jackson

[Ralph]

Kevin,

If you e-mailed pictures of your airframe, they did not arrive. Try it again...

Ralph

[KDOG]

Bah!! Ok, I'll try it again, stupid dial up...

[B8MFlorida]

Congratulations on your new job and your first order for parts.
Keep us posted on your progress.
John

Kevin, and all,

I just got my first paycheck from my new job today, and the joy I feel right now knowing that tomorrow I'm ordering materials for a flying machine is almost overwhelming. It boils down to a childlike mentality, but with the soundness of mind to make the intelligent choices needed in a project of this nature and caliber.

I'd anticipated being a few days behind you, Kevin, in construction, which turned out to be measured in weeks. But we should still compare notes. I consider a Bee project every bit as much an excersise in learning and following directions as it is learning the tools of the trade. It boggles the brain to contemplate how Bensen-Era builders shared info without the aid of forums like this. Even the best-lofted plans leave room for question. It's simply the nature of experimental aviation.

Thank you to all whom have taken the time to answer my dumb questions, or simply to encourage. I believe the support and friendship I've found here has been instrumental in both my personal and "building" life. It's been a focal point for me to aim for instead of simply giving up. Keeping a dream alive is what life's about... or why bother. I cannot imagine an existance where the simple securing of food supercedes all other interests. Yet that's how I lived for the past 2 years. It wasn't that I was too proud to ask for help...

In astuteness,
Brian Jackson

[KDOG]

Rotopix: Don't worry, you'll catch up to and pass me... I'm moving along now because I'm buying the cheap stuff! The tubing, nuts and bolts, etc. But when it comes time for the expensive stuff - rotors, engine, tail, etc - its going to come to a snails pace trying to save up the money for that stuff.

Ralph: I sent it again via a netzero email address, hopefully it goes thru this time...

[Brian Jackson]

I hear ya, Kevin. BTW, I just ordered my materials about 15 minutes ago! Waiting for a call-back from Wicks for shipping info, billing, etc. They tell me it will arrive Tuesday, which is perfect because I'm picking up the new drill press on Friday. Betcha can't guess what I'll be doing this weekend!

The engine, blades, etc., I'm opening up a savings account this Saturday that will be just for those items... I'll deposit a little every week and, if the math works out, should fund the completion of my Bee by this date next year. I'm aiming to have the airframe completed and painted by then, so the timing is perfect.

Cheers,
Brian Jackson

[Alan Coats]

RotoPix and KDOG- you guys keep up the good posts. I bought a mostly-built Bee and am working it over. Your questions and suggestions are helping me out too.

I'm not sure if the mostly-built status of my Bee puts me ahead of you, or behind you. I may be working harder making sure everything is the way I want it than if I had done it myself.

Alan

[KDOG]

yeah, Alan, you definetly should break her completely down and inspect for any defects. Thats one advantage we have. We get to see the material before its drilled and cut. But I imagine the deal puts you ahead of us...

[Brian Jackson]

...But I imagine the deal puts you ahead of us...
I concur. No doubt who will be flying first! :D However there is something magical about taking a heap of raw materials and transforming it into a thing of beauty and wonder. Oh, by the way, I just got a call back from Wicks about my order, which includes ALL the tube, angle and plate stock for the entire airframe. Came to exactly $290.40 US, including shipping! I gave them special instructions that the mast & keel tubing had to be inspected for scratches & dings before packaging, which I'm told they did. They're also marking the package "FRAGILE - GLASS" per my instruction. These guys really take care of their customers :)

Brian Jackson

[KDOG]

yeah I just shot a money order off to Wicks for the angle to do the engine mount and fuel tank mount. THen I placed an order to Aircraft Spruce for the nuts, bolts and washers. Don't ask me why I placed the orders from 2 separate companies - I don't know either. But I don't have a problem with either of them...

But hey, you're on your way!!!

[KDOG]

By the way Rotopix, your avatar is, well, interesting!!!

[Brian Jackson]

By the way Rotopix, your avatar is, well, interesting!!!
Yeah, I call it "What not to do when building a gyro"! Hey, did you get your stainless sheet yet for the shock mount... oh wait, you're using the 3/16" alum if I remember correctly. Anyway, Wicks doesn't carry the 1/8" thk. stainless sheet. Anyone know of a supplier for that? I only need 1 square foot for all the stainless parts. Thanks.

Brian Jackson

[KDOG]

Is there any plates that we CAN'T use the 3/16ths Alum for? If not, just get a sheet of the alum and go for it!!!

[Brian Jackson]

Is there any plates that we CAN'T use the 3/16ths Alum for? If not, just get a sheet of the alum and go for it!!!
That would work, but I think I'd rather stick with the stainless for the shock plate. So since I'm ordering 1 sq. ft. of it anyway, I may as well use the remaining area of the sheet for the other stainless plates called out as such on the original GyroBee documentation.

Also, the tank support diagonal braces (shown in Tan) mount coplanar to the outside surfaces of the cluster plates (yellow) and the tank mount horizontal supports (green). By altering the thickness of the cluster plates, one of two things must happen in addition:
1. Increase the thickness of the angle stock for the (green) horizontal tank supports, or
2. Add a 1/16" thk washer (AN-970-4) between the (tan colored) diagonal and the (green) horiz. support.

Otherwise, the (tan) diagonals will bend themselves into a very shallow "S"-curve when you torque down the bolts because the mating surfaces (green and yellow) won't be on the same plane.

Make sense?

Please take some pix of your build thus far and share them with us. As they say, enquiring minds wanna know! ;) . Call me sometime this weekend and we'll chat about all things Bee! Take care.

Respectfully,
Brian Jackson

[KDOG]

I see what you are saying, and like you mentioned, I am planning to use washers to compensate...

As far as pictures go, I have only high res pics of my airframe which this forum doesn't allow. I'll try to use my webcam to take a pic tommorrow and post it...

[rehler]

Brian, you stated: "Otherwise, the (tan) diagonals will bend themselves into a very shallow "S"-curve when you torque down the bolts because the mating surfaces (green and yellow) won't be on the same plane."

This would actually increase the strength by creating a slight "triangulation", which is stronger and would make the parts more stable than keeping the braces "in line" or parallel. Parallel is the weakest arrangement for any side load.

[KDOG]

Huh? Doesn't make sense... wouldn't twisting the metal weaken it? What I don't understand about the design is why not put a square piece of aluminum sheet say 1/16th in the "bed" of the fuel tank mount and use short bolts to secure it around the perimeter to stiffen the assembly, instead of having it welded and riveted. I'm thinking of a workaround for the fuel tank mount now. I'll let you all now how it goes...

[Brian Jackson]

...Parallel is the weakest arrangement for any side load.
This is true, parallelograms can skew... (hey that rhymed :D ). By the way, Ken, I'm in awe of your gyro. That's one of the coolest designs I've seen. It was interesting reading through your site.

Cheers,
Brian Jackson