Brian's Genesis G1sa Build

[willisbr]

Nicolas, John, and I spoke at great length last night and this morning and I finally came to a conclusion...another Genesis will brought to the U.S.! Well, I had actually decided weeks ago but I was waiting on the nod from my wife. My RAF is a joy for my wife and I but I want to experience the open air in a single place! I feel the Genesis is a solid choice to feed my craving to build and get the wind in my face.

I'll be starting my build hopefully within a month or two. I'm excited to be a part of the first few to build this gyro in the states. This will be my first build/fabrication ever. I hope I can do some leaning on some of the veteran builders out there for ideas and pointers. I can't wait to get started! I'll be doing a build thread and documenting my experiences as a amateur builder. One of my goals is to show MYSELF that I can do it...hopefully this will radiate to other new guys and generate more interest in our sport.

http://aviomania.com/user/cimage/new-1.gif

http://aviomania.com/usertpl/1vg125-simple/aviomania-logo-new-midium.jpg (http://www.aviomania.com)

[StanFoster]

Willisbr- Great news! I am telling ya, this gyro is going to rock. Just another great choice to choose from. I will be looking forward to your build thread. Stan

[barnstorm2]

Congrats!


.

[All_In]

I've been getting to know Brian so much better! He is a good man, husband, and father of two daughters!

Welcome to the Genesis family Brian!!!

How cool is that! Brian will have two rides. A two place with cabin and now a yank and bank dream come true. Man does he have a good wife or what!!!


Way to go Brian!!!

I cannot wait for the build thread and so glad there will be a new Genesis in Florida...

[willisbr]

Awaiting arrival of the construction videos and plans. My kit should be complete and ready to ship by February. How exciting!

This week I have been getting my shop ready. Tools, work bench. Need a space heater!

Decided on a painter for powder, automotive, and ceramic coatings. Still working out a color scheme. I like Aviomanias tail design with the striping and stars. May keep this but with different colors. Don't know yet. Some initial ideas are white with blood red control/suspension tubing and some red decal work on the tail and nose. Still playing with some other ideas.

Waiting on more good news from Nicolas. Excited!

[StanFoster]

Brian- I can't wait to watch your build. I can feel the excitement. I have learned a long time ago that a job well planned is already half done. Looks like you are off to a good start already, Stan

[All_In]

Yo Brain!!!

It is exciting and you are doing it right. New work bench, new knowledge on how not to hold a part you are drilling. You are a builder now and have the war wounds to prove it!

I like the colors and power coat you emailed me it will look 1st class!

Also Nicolas will create those strips or any other graphic you wish for you and I think in just about any color.

[willisbr]

I just received an email from Nicolas this morning giving me an update on some shipping hurdles. Apparently the authorities get a little antsy when you try to ship a small package that is declared as aircraft plans.

I'm looking into registering for a Rotax course a few hours away in Mississippi. There's an intro course and then an intermediate course. Want to learn as much as I can about dissassembly, assembly, preventative maintenance, and overhaul. From some of the videos I have watched, I feel that I am up to the challenge of doing all of this. The confidence in my engine is going to be best realized by me learning every single thing about it. I think that is why I'm so looking forward to this total build project.

[bushflyer]

Hi Brian,

I'am waiting so excited that someone drops a note indicating a Genesis
or parts of are received.
Maybe Nic should alter the declaration into aircraft picture insted of aircraft plans

Looking forward awaiting your posting
Guenter

[willisbr]

Well I came home today to find a note on my door that my build plans DVD has arrived in the states! But I have to wait and pick it up tomorrow. If the damn cat can't sign for my deliveries when I'm away what use are they? Another day goes by,

[All_In]

More good news Brain, now you can start building in your imagination making it easier for the real deal!

[willisbr]

The build videos are amazing! I've been watching them all morning and getting familiar with the meticulous techniques that Nicolas explains in zoomed, thorough detail. I also received my blown up color cad drawings. Huge! Each sheet takes up my whole table. Going strait on my shop walls this week. I'll post some pixelated shots so you can get an idea of the completeness. Have to honor the proprietary agreement. Lastly, the engraved Aviomania Genesis serial plate. My wife came home and was excited to see all of our material. Now she's wanting to help. How awesome. We are going to have a DVD night!

[StanFoster]

Brian- The more I communicate with Nicolas, and seeing your excitement over the videos, just reinforces Johns excellent choice of teaming up with Nicolas. I feel even in this down economy, this gyro is going to sell over here. By the way, I have my foot in the door with KitPlanes. One good article in that major newstand magazine is going to really help sales, imho. With your build thread and mine, this will put on a blitz! Stan

[WHY]

Just hoope Nicolas doesn't run into a logistics and supply problem or finding enough qualified help to expand because he sure is going to need to expand. :) :) :)

Tony

PS and wait until he hits the market with a ultralight ?????

Tony

[All_In]

... How awesome. We are going to have a DVD night!

You are a lucky man... and have a very special wife!!!

[Joe Pires]

I missed this thread when it started. How exciting. Congratulations.

[Irishpilot]

Brian,

What options did you get (or getting...) to include engine. I am very interested in what you think of the build process as someone, like myself, who has not built an aircraft. The price of the Genesis is something that even an 'overpaid' government worker married to a teacher could afford if I ever get kids out of college ;-) So let us on the forum live vicariously though you as start this process! A workshop heater in Florida...isn't that just a sweatshirt? :-)

Mike

[helipaddy]

Congrats Brian on your choice of build, I think you have made a great decision.

[willisbr]

Brian,

What options did you get (or getting...) to include engine. I am very interested in what you think of the build process as someone, like myself, who has not built an aircraft. The price of the Genesis is something that even an 'overpaid' government worker married to a teacher could afford if I ever get kids out of college ;-) So let us on the forum live vicariously though you as start this process! A workshop heater in Florida...isn't that just a sweatshirt? :-)

Mike

G1sa
Rotax 582 with E box
Europrop? (Ukranian)
Upgraded nosewheel and suspension
Mechanical prerotator
24' Dragonwings

I want to make some Genesis T-shirts!

[All_In]

...
I want to make some Genesis T-shirts!
I was thinking of the same thing!!! Let compare artwork?

[willisbr]

I emailed Nicolas about this last night. Working on it this weekend and will pitch it to you two. :) John you gotta wear a polo at BD though since you will be the boss. lol In ironed jeans and a comb over.

[All_In]

I emailed Nicolas about this last night. Working on it this weekend and will pitch it to you two. :) John you gotta wear a polo at BD though since you will be the boss. lol In ironed jeans and a comb over.
Great news!!! Thank you buddy!!!

[willisbr]

Nicolas advised that my paperwork is ready to be submitted to customs for review. My kit will make it's way to the airport near the end of the month.

I opted to build the tail assembly myself vice having it sent pre-made. I wanted this experience with rivetting, etc. I'm pretty excited and intimidated by this all at the same time.

I'm still considering some engine solutions as I have recently started reading more about Yamaha and Webber engines. My original choice is the Rotax 582 with Ebox but a four-stroke sure sounds appealing. I've been sending private emails around all night so I'll see what info I get back this week. I'll have plenty of time to finalize this decision.

I'm going to be designing some Aviomania Genesis shirts when I get some artwork from Nicolas. I think shirts in general are a great way for us mysterious pilots to show the public what we do. "What the heck is that?" Instant conversation. My simple RAF polo has stirred up many conversations around town.

I'm excited to get down to Bensen Days this year and meet up with Stan and John about these projects. So much to talk about in person. I anticipate Stan will be well along the way with his project and I should be not to far behind. Hopefully the shippers will be kind to me now that the holidays are over.

[All_In]

Oh good it's a race!!!

[willisbr]

No! lol Stan believes this is furthest front the truth. :)

[All_In]

Just play'n guys!!! Trying to stir the pot. :flame:

But I am checking with Vegas for the current odds to handle the forum betting, just in case. = :angel: NOT!

[All_In]

Yikes do not do that!!!
OK I'll be quite now...

[willisbr]

Lol you guys. No race. This is a learning experience for me all the way through. But to add to your joke stan...maybe we can see who can get one together with the least amount of bolts. Aluminum bolts! No washers. And hand tight only. Wrenches down! ;) you guys have a great day. Awesome weather in north Florida today.

[willisbr]

I received more instructional DVDs for suspension and parts fabrication today. Kit shipment should be soon. Been working on cheapest route for shipment, courier to door, and brokerage into country.

I brought home my Rotax 582 blue head complete with e box, exhaust, and radiator from Bensen Days! I have some minor cosmetic changes to make. I also need to change out the gear from 3.0 to 2.62:1. If anyone knows where one is, let me know. Will purchase or trade.

[willisbr]

Here are some pictures of the engine and miscellaneous.

Uploaded from my iPhone 4.

[All_In]

Looking GOOD Brian! I'm going with the exact same setup!!!

[FixinFool]

Hey Brian, New member here,enjoying yours and Stan's progress with your Genesis builds. I am only about 3 hrs from you in east central AL. ,cant wait to watch yours go together. Frank Futch

[cardioflow]

I look forward to watching this come together.....and dream of mine in the future.

[willisbr]

I started working on a few things tonight, mostly the rudder pedals, engine mount, and some odds and ends.

I learned a lot tonight so I'm going to ramble some thoughts here. First, I don't know how I've made it this far in life without a miter saw and a bench grinder. When I ran out of stuff to cut, I started looking for other things around the garage that needed "modifying". I got a buffer wheel installed on the grinder. Tried my hand at getting a few blocks of aluminum polished. Prett easy.

OK, so my plan tonight was to cut and drill all of the materials that I had tonight. Mission accomplished. I need to get a sand wheel so I can round off some edges. I was going to complete both of my rudder pedals but I ran out of solid rivets. I cut, drilled, and layed out the parts on my large diagrams...keeping up with my inventory. Once that everything is rounded, sanded, and prepped like I want, I'll tag them and store them out of the way until needed.

My complete kit should be landing in the USA on Monday. Broker, customs, and then off to the courier straight to my house. Getting excited. Enjoy these pics.

[GaryMac]

Alright!!! Another one starts to take shape. Good luck with your build, Brian.

[willisbr]

I went and added to my power tool collection today...again amazed I've gotten this far in life without a disc sander. I've been playing in the shop all evening. I have decided that my drill press is worthless and so will be at least starting most holes with a hand drill.

I sanded all of the parts I have and worked on some polishing. The two brackets in the first pictures below were tonight's biggest challenge. Once I was satisfied with one of them, I married them together and mirrored them on the sander. Exact replicas. These will be powder coated with the rest of the frame so a light sand overall did the job.

Enjoy the pics.

[willisbr]

The word is that the Genesis lands in San Diego sometime today. John will be working on getting it cleared through customs and loaded onto a ground transport. I hope to have me some crates within a week or so!

Question: Polished aluminum scratches if a fly lands on it. Is there a coating I could use after polishing a part? Wax, clear coat? Thanks

[All_In]

Looks like you are doing really nice work to me.

The broker and I are ready and I've got shipper fighting over the bid's to ship the parts directly to you. U-Ship lets you post your shipments and the bid on them for those who ship you should check them out. We'll soon see how they perform?

[willisbr]

The kit just cleared customs. John is working on getting the kit to the ground shipper by the weekend. Front door delivery. Yes sir. Can't beat that. Thanks Nicolas and John.

[willisbr]

I fabricated some nosewheel brackets and the nosepod support bar tonight.

I did a bit more sanding of some parts. Fine tuning. Getting bored waiting on the other parts to arive.

One major thing I'm proud of...I make it a point to clean my working area better that I started after each build night. All tools away, blow off the work area, vaccum, tidy up the parts, empty the trash, finish the beer, wash hands, kiss my wife, go to sleep.

[willisbr]

I received my hardware and round tubing shipment today and did a full inventory. Then I cut the main angle round tubing to size and drilled some holes. I also fabricated the tube inserts to strengthen the them under load. Lastly, I made another rudder pedal support tube. The first one had a mismeasured hole. Cleaned shop.

John and Nicolas emailed me and Gary today. The kits have cleared customs with no problems. John is working on making a special box to repackage everything for ground transport.

Good night.

[willisbr]

John has been working his tail off trying to get this ground shipment thing done. Custom made boxes, pallets, shrink wrap, burly/sweaty delivery truckers, insurance rates...good grief! Thanks John for your efforts. I see an opportunity to develop contracts in the future with a shipper and broker in the future if they do us right. Ironing out the kinks at this time.

Latest and greatest...trying to figure out why I thought I would need two left rudder pedals. Hmm...I can't think of a reason. Guess I'll have to toss one and make a right one. Oops. First deposit into the bucket of damn. Have a great day all. :)

Oh and Todd helped me change the title to my thread so it received appropriate traffic and made sense. Thanks Todd!

[GaryMac]

Yep, it's official. If you have a scrap bucket, then you have a project.

I had to order more aluminum from aircraft spruce, cause I messed up on a rudder pedal, too.

A few kinks and hurdles are needed to get things started, but I bet that we will both be building like mad men by next week.

Good luck with your build.

Gary

[willisbr]

Gary, I needed more angle. Nicolas split 2x2 for the angle an I suppose he used a table saw with a jig or guide. Sound right? What did you do? I don't have a table saw and doubt I will buy one.

You're right...it's gonna be crazy next week! Coming down to the wire. John has been emailing me more than these prescription pill scam sites this week. Good stuff :)

[WHY]

If you have a SCRAP PILE then you hold a degree in "advanced experimenting"

Tony

[GaryMac]

Hey, Brian,

I just ordered 1x1 6061T6 angle... it's a little wider than the original parts that Nicolas sent, but worked fine for the pieces that I messed up. Just make sure you account for the difference in size from the original pieces, when laying out any holes to be drilled.

I went ahead and ordered some 2x2 tubing, and some various sizes of angle, all because I know somewhere down the road I will need it, and because I needed some stuff to work on for the engine mount.

[willisbr]

Great idea Gary. I'll do that this week. Either I need a better set of drill bits or work on my method. When I punch where I'm going to drill, the bit wanders or bends a bit and I occasionally end up with a hole a little off. My punches are precise...the final sucks. The drill press isn't the best but it isn't the worse. What's the secret? Since, I've been using a hand drill to start the hole or go all the way through with a pilot hole. So what's the point of a drill press? Need some advice. Thanks.

[GaryMac]

I'm no expert, but the bits I'm using are "pilot point tips" from DeWalt. Use a center punch to mark your spot, then line up the pilot point tip right in the center punch mark. By using light pressure on the drill press to start with, my holes are coming out OK. I think the trick is to just go slow, with light pressure.

I'm sure someone with more experience can give you a better answer than me, but so far, so good with this method.

Here's some pics of the bits I'm using....

http://i846.photobucket.com/albums/ab29/GaryTexas1/2011%2005%2015%20HKS%20Alternate%20Mounting%20Meth od/IMG_2641.jpg

http://i846.photobucket.com/albums/ab29/GaryTexas1/2011%2005%2015%20HKS%20Alternate%20Mounting%20Meth od/IMG_2643.jpg

[JEFF TIPTON]

Brian you could use a smaller bit to make a pilot hole and then use the final size.

[Lee Scatt]

Hey Brian, By all means invest in quality bits. The aggravation you avoid in the long is worth it.
I have had great results predrilling all holes with a 1/8" bit. It will usually start right in the punch mark.
The press is used for the final, for you want it to be square thru.
Don't scrap that rudder pedal, the next Genesis builder can use it!

[willisbr]

Thanks guys. I'll go look for some new bits and continue doing pilot holes.

[GaryMac]

One final thought... if your drill press is new, you have to go through a "true up" where you check the table versus drill to make sure everything is square.

I bought my press just for this project, and luckily it was square both ways. I re-check it every now and then, just to make sure the table has gone out of whack versus the drilling head.

[Lee Scatt]

Brian, These folks are great. www.use-enco.com.
Fast service, almost anything you will need.

[All_In]

Yo Brian and Gary!
It is about to get much more fun as it's repacked, and strapped to pallets.

I have to admit I never gave credit to packing people. I have so much more experience unpacking things I buy and never thought about all it takes to ship large items.

Here is a very bad cell phone picture of my handiwork as a packer.

[ynot]

Brian,

Just to add 2 cents to the accurate hole problem. I use a center drill to first drill the pilot hole. They won't flex like most small drill bits. You can get them at most machining supply houses such as Enco (http://www.use-enco.com) or Victor Machinery (http://www.victornet.com).

Here is what they look like and you can get them in various sizes.

[Mark E]

Hi tech solutions are best - but I once helped a friend (machinist) drilling a huge amount of holes in some aluminium brackets, using a very shoddy drill press we had. My attempts at precise clamping always caused wandering as the press flexed.

He just set the clamp jaws very loose, allowing some movement in the work piece, and the drill tip simply stayed in the punch hole. He just kept dropping them in there, the drill centred the piece, and he churned out thousands in no time.

[willisbr]

Got another two hours in the shop tonight. I received my tires and wheels today. The wheels call for a few drilled holes and installing drums. Not too difficult. I escaped the night with relitively clean hands.

I also received the 2.62 gear swap for my E box. They look great. There's a bit of grit and gum inside the front plate. While I have the box apart, I want to go ahead and clean it up before I reseal and fill with oil. Can someone advise the proper way to clean the gear box internals? Thanks!

Nicolas, I got my 2.62! :)

Good night all.

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[Earthboundmisft]

Brian, use spray brake cleaner from Autozone. Carb cleaner works great too, but is more agressive. What are you going to do with the RAF once the hot-rod is done?

Hope the engine doesn't freeze up from sitting...:boink:

[willisbr]

Thanks mike. Just spray and re-fill right? No grease?

Keep RAF for CC and flying the fam.

[Aviomania]

Good Brian!!!! now you will get all the performance out of this 582!!!!

[willisbr]

Tracking number shows that the kit is in Pensacola. I contacted the facility it parked at and tried every angle I could to come pick it up today. Apparently I'm not more important than the five trailers ahead of me that remains to be unloaded. Oh well. Another day goes by. Guess I needed the extra night to continue setting up my new man cave.

[willisbr]

I received my kit today. My wife went and picked it up from receiving downtown. What a lady. :) packaging was top notch. Wrapped better than grandma's fruit cake we used to get in the mail every year. Anyone getting into Aviomania better also buy some stock in bubble and plastic wrap because it's used liberally! Jaley helped me unpack and run and inventory. Here are some shots.

[GaryMac]

Alright, Brian..... glad you got it and everything looks to be in good shape. Now it's time to make the chips fly!

[willisbr]

Last night I spent many hours in the shop sanding brackets, plates, beams, tubing. Everything that I have in first stage has been sent to the painter for powder coating today. Nose, wheel pants, and tail will be painted last as soon as I develop some more inspiration on what I want. The paint guy estimated a week or two turn around time...so I'm twiddling my thumbs until then. I decided to have the paint done first so I assemble and disassemble only once and to make sure I compensate for the difference in measurements from paint thickness. Disassembly and reassembly of the frame is recommended at least once to deburr holes and dump out all of the drill shavings. I'll be working on some towels laid out in the shop until I get the keel on wheels.

[GaryMac]

Brian,

I think your "paint then assemble" plan is the way to go. I struggled with that decision, and decided that I had to assemble first, due to the special engine mounts for my application. I only wanted to go to the powder coater one time.

You'll get a great fit doing it the way you have planned. Good luck!

[All_In]

Interesting approach Brain. It will be less work I just hope there isn't a reason Nicolas advises to assemble with smaller bolts first and then paint and reassemble.
Cannot wait to see you start really putting her together.

[willisbr]

John, my understanding from Nicolas' preference was to paint, assemble with some smaller bolts, once each area is determined square nicely fit, finish up with proper sized holes and bolts. Disassemble to deburr and remove shavings, reassemble. I'm still going to do the process Stan and Gary have done, only elected to paint first.

Gary, that totally makes sense. That's going to be perfect anyway since it seems you are using the smaller bolts anyway for now. Going to be nice :)

[All_In]

Hi Brian
It will be a good comparison in building time and procedure.

[willisbr]

You should put little "easter eggs" all throughout the gyro, Stan...little etches or something that only you know about. Would be funny to write something under a plate only for John to find years later when he pulled it off to change something. "Stan was here!" :)

I think it's cool that each of us are doing it a little different...keeps our threads active and interesting!

I too have been hit with a schedule overload. Moving into the new "ranch" has taken a toll on me. I HATE moving. Thank God I have found my dream home and will never move again. I have only had time to inventory, prep, and get the parts out the door for paint. The REAL reason I pushed them out the door instead of put it together now (which is what we all really want to do secretly anyway! :) is that I don't have time to do anything for two weeks. Hahah :)

[All_In]

I like that Brian. Stan was here!!!

I hate moving too and now I really understand with your time constrains.

[willisbr]

The quote I got from our local powder coater is $530 for the first stage. This includes frame tubing, 29 brackets, suspension tubes, nose wheel support, engine support rods. Don't know much about paint costs but these guys are who everyone else goes to. After this, the additional paint needs are the tail, some brackets near the rotor head, and some other small areas. How does this sound?

[gyroplanes]

Hi Guys,
I have been too busy to read this thread, so forgive me if this has been covered.
The FAA is vigilantly checking paperwork and other requirements these days.

I would make a builder's log in accordance with the FAA guidance (FAA.GOV) and fill out the 51% rule checklist as you go along.
Dot the i's and cross the T's well % proper.

Also, check out you tube as many are now doing their own powdercoating. Our chapter can build an oven unit big enough for an airframe keel tube and buy the coating kit from Eastwood (or harbor freight) for less than one hired out airframe coating.

[willisbr]

Tom can you send me or attach the 51% document to the forum? Any references would be helpful. So far I have been taking pictures and Doyle tong hours spent and procedures. I would like to call you soon to check my practices.

[Earthboundmisft]

Go commando Brian. Polishing is cheap. Labor intensive though.:der:

[All_In]

I need a copy of that to give to our customers too!!!

The only thing I can find so far searching the net is a link to one of Greg G's posts from 2008 with that version of the check list.

Here it is:
http://www.rotaryforum.com/forum/showthread.php?t=18036

Thank you Tommy for the heads up!!!

[gyroplanes]

Hi guys,
I have been upgrading my website www.calumetair.com I have upgraded most forms and have been adding "buy it now" and 'Shopping cart" buttons for commonly purchased items.

Click on DAR services and under forms & checklists, you will find the current checklist (for other than airplanes only) I believe we are VERY close to having a new 51% gyroplane checklist approved. I will let you know when it happens. The new checklist should be favorable to gyros and is gyro specific. The FAA has been VERY, Very co-operative with us. Thank Greg Gremminger for dilligently working on this.

[All_In]

Thank you Tommy and Greg!!!

You guys both ROCK!!!

[gyroplanes]

John, It's not so much a "rock" as a "waddle". (for me at least)

I revised the checklist site when I realized the old (non-airplane) checklist has no instructions. I have since downloaded and uploaded the "Airplane" checklist, which has the instructions.

It is my intention, when I get caught up with work, to post all of these latest forms and instructions on the PRA website. I'd like to see the PRA site become the repository for all things rotorcraft.

[All_In]

That is a great idea Tom.

Thank you for all you do for us!!!

[willisbr]

The frame components are back from the powder coater. Spent all night in the hangar working on some keel and mast stuff. Here are som pictures of the re-inventory. Everything was nicely wrapped in foam. I'm very pleased with their work.

1. Frame parts inventory
2. First look at the quality
3. Frame parts inventory
4. Impressed with the gloss
5. Keel and brackets
6. Keel brackets
7. Prepping keel for first cut
8. First cut, looking good

[GaryMac]

White!! I like it, and it looks like you got a good job on your powder coating.

Did you have to do anything special, as far as instructions to them on the temperature?

I'm going to try to get mine to make sure they don't go over 375 degrees in the process, but I still need to pick a color.

[willisbr]

1. Setting up for critical cut of keel
2. Masking for primer
3. Primed inside joint for corrosion protection
4. Bracket fits perfect
5. Bracket complete
6. Mast plate
7. Keel progress
8. Mast support tube installed

[willisbr]

1. Attaching the mast halves
2. Securing the mast to the keel
3. Mast brackets for engine support
4. Mast brackets for engine support
5. Finishing the mast/keel bracket
6. Done for the night

[willisbr]

Thanks guys. I believe the standard is 350-400 degrees. The powder coat is thick stuff so be prepared to see some offset when reassembling. Nicolas' recommendation to assemble with a few smaller bolts first is a smart idea. Working like a charm.

Gary, I didn't have to do anything but file edges. No pre-sanding needed. They bead blasted, primed, etc. I did sand all of the plates and brackets by hand just for the hell of it but when I dropped it all off he said it was not necessary.

[GaryMac]

That's good information to know on the powder coating, Brian. Thanks!!

Looks like it's coming together well on your build. Are you going straight to the AN bolts, since you powder coated first?

Looks really good.... keep the pictures coming!

[willisbr]

I have some smaller dummy bolts for squaring but I'm going ahead and working my way up with final hardware. Debarring along the way and dumping shavings often.

[Dirtydog]

willisbr : Looks good I didn't know you were doing a build.

[choppergabor]

Wow Brian I do like the powder coat! That looks very durable and very professional. I like what you have done so far. Good job my friend :)

[Aviomania]

Brian Very nicly done, exelend powder coating!!!!

if you are going straight with an4 it maybe good if you use normal nuts (1/4" UNF).

you may find that later you may need longer bolt to add some more parts on.

If you go this way then when finished you go through all nuts, replace and torque to proper value

[Dirtydog]

Aviomania : How true, I'm not sure how many times I had to remove something to add something. My 2nd build, I'm using reg nut & bolts until the thing is built. Then change them out

[Resasi]

I must have missed this particular thread, not sure how, but have read it through twice just now. Great thread, and really good to see these two quality machines going through two very exciting builds, sorry three. Almost forgot you Stan and John, guess it's the two week syndrome kicking in.

You guys are really doing great work with lots of good info and pics for the next buyers. Love your pictures Brian, you really an inspiration to guys who want to start a build but worried about their competence to do it

Nicolas seems to have done a really fine job on the production and I am sure he has started to build up a following in Europe too. France seems to have a very vibrant gyro community with a pretty relaxed and light-handed approach by the authorities. I know that one of our light gyro makers and rotor blade producers has decided that is where he wants to do more business.

Tom thanks again for helping and guiding us with the Feds and their requirement, together with the work that Gregg does for us, it's people like you who help keep this sport alive and developing in a healthy way.

Since I know that very soon these two are going to have air under those tires, I am just sitting back and enjoying all this detail on what goes into a really fine build process.

[Resasi]

Funny Stan, I was just writing in the other Genesis thread about engine choice.

I know John has said he was going with the 583. What, if any, choices have been made with regard to rotors and props?

[willisbr]

Nicolas, the plans call for a thin washer on the bolt head for the keel bend plate. I left these out because of the thickeness of the powder coat. This is ok? Regular washers at the nut.

[Aviomania]

1 thick washer = 2 thin washers.

If you have more than 1.5 threads showing after the nut as it is it will be better to use 2 thin washers on both sides. If not... then leave the head washer out and use thin under the nut.

the 0.250 thick plate and the round protrusion under the head of the AN bolt will have no problem on that particular place.

[willisbr]

More work in the shop last night. Worked on installing the front nose support tube, suspension brackets, engine support brackets. I have misplaced a piece, so my eight hour session halted at 4AM. Sad. Guess I'll have to order some bar this week. I can't find a piece of bar that helps press the mast against the vertical engine support tube. Ugh. I know I made it. Enjoy the pics.

[willisbr]

Suspension brackets and engine support plates. I'm squaring as I go to make sure plates and brackets are even.

[willisbr]

Engine supports.

Reiterating that this powder coat is thick. For those that will be doing pre-assembly before paint it will be imperative to preassemble with smaller diameter bolts and then enlarge to pried size during final build. Gary and Stan are doing this so this info is for future builders. If not, there will be problems.

[willisbr]

Finishing up the night.

[GaryMac]

Very nice.... it's coming together, and looking good.

[willisbr]

Thanks guys. Gary, what are you using for a build log? Thanks.

[willisbr]

I just want to give a :first: to Nicolas. He's been very helpful during this project so far. Answers emails within 24 hours, his recommendations are spot on, helped me correct a few mistakes by sending me a lost part or botched angle, and is all around easy to talk to. He knows this gyro inside and out and wants those working with him to have a great build experience. I'm AMATEUR through and through and he is helping me turn pro. Thanks Nicolas!

[GaryMac]

I second your comments on Nicolas' support. I have yet to talk to him on the phone (have not needed to)..... his e-mail support is outstanding.

As far as build log.... I went to kitlog.com and downloaded their free trial software. I went ahead and purchased it..... it's not complicated, very easy to use, and does not "overkill" the problem. I found it very easy to use, and I like the reports that it produces.

Good luck with your build... looks great so far.

[willisbr]

More work in the shop tonight. My dad gave me a hand installing the diagonal tubes, inserts, and brackets. A pretty easy night.

[Resasi]

Coming on very nicely Brian. Is your Dad into flying gyros?

[Lee Scatt]

He will be.

[willisbr]

He's a 20+year helo pilot and he's also got gyro rated with me. He called me last night at 10:30 when i was sleeping and asked if he could come over and help work on the gyro. So I got up and we went to work. Is he into gyros? :)

[Mark E]

.... called.. at 10:30 when i was sleeping and asked if he could come over and help work on the gyro. So I got up and we went to work. Is he into gyros? :)

Something very nice about that little story! :-)

[willisbr]

Tonight I installed the engine support bars, tubes, and brackets. Next I will be getting the seat support and landing gear installed.

[Resasi]

Hmmm, Brian my daughter-in-law would take a pretty dim view I have great regret in saying. Your wife on the other hand seems to be extremely understanding and supportive. She is a rarity and a gem to be treasured.

[willisbr]

Another all-nighter. Installed the seat support and the main gear. This project included installing bushings and rod ends on the suspension tubes, cutting and drilling the struts, and installing the brackets on the keel that secure the struts. It took all night to do this because I had to sand some bushings down for fitting and...because steel is a pain in the ass. Recommend drilling out all of holes on the steel landing gear prior to sending it to paint. Steel takes longer to drill and thus paint chips and deburring is a bitch. Kim came out to the hangar with popsicles around 4am. I was more of a mess than I thought and so she snapped a picture. Aluminum, sandpaper dust, and buffing residue all over my face. Enjoy the pics. Good night.

[willisbr]

Here's a few more on her main wheels. Sort of. I want to get the nose wheel done tonight then I'll finish up the mains.

[ckurz7000]

That looks like a high-power high-class build so far. I hope you're enjoying yourself as much as I enjoy reading about the progress.

-- Chris.

P.S.: If you're allnighting with the building what do you do during the day? Do you have a piece of advice that I can apply to my life?

[Penguin]

Brian:

That's a good looking build on the gyro.
Not so much on the fabricator! Put some clothes on, man. Some of us look at the forum while we're eating!

That's a seriously good-looking build. Can't wait to see her fly.

[willisbr]

Thanks guys! I work at night mostly because the heat in the day is unbearable. Just taking advantage of the long weekend. I rarely work on it during the week. Oh and the secret is keeping my wife happy during the day so I can sneak out at night. Shes happy that I have a hangar to work in instead of the garage...keeping her up all night.

[willisbr]

I got the nosewheel and the brake pads installed tonight.

Thank God for eye protection. I almost took my eye out making some bushings. Even with my safety glasses on, I still managed to cut the piss out of my eye lid. I think I will invest in some goggles and toss these glasses. That was too close.

Enjoy the pics. Goodnight.

[Georgi]

Brian,what wheels do you use?
Thank you.

[Jens]

Brian, what you are doing looks great.
And that Genesis seam to be a fantastic kit! Hard not to want one..

http://www.rotaryforum.com/forum/attachment.php?attachmentid=82873&stc=1&thumb=1&d=1309935328

[willisbr]

Brian,what wheels do you use?
Thank you.

I'm not sure the make. Nicolas would have to answer that one. They were shipped from the USA probably from a tractor supply if I remember.

Here's closeups http://www.rotaryforum.com/forum/showpost.php?p=422617&postcount=64

[Aviomania]

They are Azusa 8" wheels you can get them from aircraft spruce or wicks. Nose wheel is azusalite 4"

[Brent_Brown]

I have pdf drawings to mount a disk brake to that 8" wheel. you will have to wait until I get home before I can post them but they do work and look good. I have them on the 670 gyro.

[willisbr]

Tonight was fix stuff night. I had a rudder pedal support bracket that I wanted to square off better. I ordered some angle and fixed it tonight. After that, I secured the nose pod support bracket. Then I measured and cut the keel slot on the nose pod. Lastly, I made a seat mod and turned the Genesis into a three seater. Pics self explanatory. Good night.

[Timchick]

Lookin' good, Brian. I'll be back in Milton in a week. I'll get up with you so I can come check it out.

[Dirtydog]

willisbr :Coming along pretty good....

Did you get the comment I made about using the cordless skill saw to cut the metal or have you found a better way..??????????

[willisbr]

Worked on my engine mount plates today. I had a nice used plate from when I purchased the engine. So I traced out what I needed, saving as much as I could of the remaining plate.

The remaining challenge is trying to figure out how to cut out the inner area. Review the pics. Can someone give me an idea? Thanks

[StanFoster]

Brian- first of all, you are doing a very nice job on your build. One way you could cut the bottom cut on your aluminum, I have set the saw fence on my table saw leaving the correct amount. Have the blade completely lowered , center the cut over the peak of the saw blade, turn the saw on and slowly raise the blade and saw to the angled corners. Check your cut several times and don't cut past the angles, of course! Flip it over and repeat. You then can take a saber saw and finish cutting. You can also use a carbide router , 1/2 inch shank with a pattern following bit to cut this instead of the table saw. A table saw can be used to make many notches and remove it that way. Or someone with a water jet could do it, but I am sure you are like me and want to do it yourself. Stan

[willisbr]

Another few hours in the shop and the result was two engine mounts, ready for a few more holes and a final polish. These things were a pain in the mast.

I am going to be planning my instrument panel this week. I keep going back and forth between a few ideas. Trying to decide between full steam gauges, MGL digital gauges with combined indicators, or a small MGL EFIS such as the Enigma. Can't decide. Anyone have experience with these MGL products?

I'll be going with a Microair round transponder, and the XCOM or MGL radio.

Question: when one buys a transponder, do I need to also buy an encoder? What is the purpose of this? An MGL instrument I'm looking at has an encoding altimeter. Trying to figure out if this is helpful. Can someone please explain what I need to be looking for? Transponder is necessary for me as I live 1400 below class C. Thanks all.

Comments?

[PW_Plack]

Question: when one buys a transponder, do I need to also buy an encoder? What is the purpose of this? An MGL instrument I'm looking at has an encoding altimeter. Trying to figure out if this is helpful. Can someone please explain what I need to be looking for?

Brian,

There are three modes of operation for typical general aviation transponders:

Mode A - Simply responds to being hit by the radar beam by transmitting a string of pulses encoded with your dial setting (the four digit number set by the panel knobs).

Mode C - Responds with the dial setting plus the pressure altitude (what your altimeter would read if always set to 29.92).

Mode S - Responds with all of the above plus an identifier unique to your aircraft registration for automatic ID on the controller's screen. (This code is assigned when you register the aircraft, and the number can be found on your aircraft's listing in the FAA database.)

For either C or S, your transponder needs to be fed a digital signal from an encoder connected to your pitot system's static port. The encoder is simply an altimeter which is permanently calibrated to 29.92, and creates a coded output signal instead of displaying on a meter face.

A "blind encoder" is just a little box which connects with a serial cable to your transponder.

An "encoding altimeter" is a single pressure sensor which drives both a meter face and the serial output. When you adjust the Kohlsman window in the altimeter to the actual local barometric pressure, it leaves the digital stream calibrated to 29.92.

Until recently, encoding altimeters were a more expensive solution than a separate blind encoder, but saved space. If you're equipping a panel from scratch, I'd guess you can get MGL's all-in-one encoding altimeter for less than a stand-alone altimeter plus a blind encoder.

Another advantage of the encoding altimeter is a better assurance of compliance with FAR 91.217, which requires your in-cockpit altimeter and the encoder feeding your transponder agree within 125 feet. Obviously, if they're fed off the same pressure sensor, slight changes in the sensor as it ages will affect both readings the same, keeping them in agreement.

Given their selling price and size, the MGL altimeters almost certainly use solid-state sensors, rather than an aneroid (bellows-type) sensor. At one time, the solid-state sensors were more troublesome to keep calibrated as they aged. That may not be a big deal anymore.

Some combinations of encoder and transponder require an adapter to translate the MGL's RS232 output to a different serial format the transponder can use.

Many gyroplanes have static ports located for convenience rather than accuracy. You'll need to make sure you've chosen a location for the port which is not affected by shadowing by the pod, etc. (If your altitude changes from standing still to rolling down the runway before takeoff, you got the wrong location.)

[Earthboundmisft]

All ya need is a radio, tach, coolant temp, and egt. Keep it light.:rant:

[Lee Scatt]

All ya need is a radio, tach, coolant temp, and egt. Keep it light.:rant:

All those gauges are used for setting the thing up. And control towers still have light guns. Leave em on the ground, make it lighter.

[willisbr]

I'm not instrument whipped but I do have a few minimums engrained in my mind. I think I'll go with combined instrument options to save weight and real estate. Most likely, two or three MGL round units. I am located in between two surface class C radials so getting up and out is not just standard pasture flyin'. Lot's a military and airport opps within 10 miles. Plus I like reading. :)

[ckurz7000]

Why not go with the MGL Enigma? It takes pitot and static pressures for altitude, speed and vertical speed info. Plus it displays all the engine parameters, fuel level and flow, compass heading and attitude, etc., etc. Plus it also has a great GPS built in, is highly user configurable (you like to read, right?). On MGL's website you also have a simulator for downlading that'll let you play with it on your PC just like the real thing.

-- Chris.

[Resasi]

A lot for equipping a gyro perhaps, but for the money those are extremely sophisticated multifunctional units.

Certainly well worth thinking about for cross country touring machines.

[willisbr]

I think the enigma is going to be excessive in price and feature for this application. I had originally considered it but I think I can do a more simple setup. I'll probably install my garmin 296 in the panel with the square bracket accessory.

[All_In]

Wow!!! Way to build Brian.
You have gotten a lot done is a very short time... Nice work buddy!

Also you might wish to check out Trig transponders!

http://www.trig-avionics.com/products.html

My aviation repair shop recommend Trig over Microair for my transponder!

[willisbr]

Also you might wish to check out Trig transponders!

http://www.trig-avionics.com/products.html

My aviation repair shop recommend Trig over Microair for my transponder!

How did you decide this? Trig is mode S only which I think is better than C?

[Friendly]

Brian,
your motor supports really cleaned up well.

[All_In]

How did you decide this? Trig is mode S only which I think is better than C?
Hi Brian!

The recommendation was based on the number of repairs seen in his shop as he felt they both preformed about the same. He also recommended the Flight Line FL-700 VHF Transceiver over the Microair which he see's much more often.

As to Mode S, yes Mode S transponders are compatible with Modes A & C.
Mode S (Selective) is designed to help avoiding overinterrogation of the transponder (having many radars in busy areas) and to allow automatic collision avoidance.
This is the transponder that makes the ACAS II (Airborne Collision Avoidance System) and the ADS-B (Automatic dependent surveillance-broadcast) systems function.

[willisbr]

The only thing worse than waiting on parts is getting home with a note stuck to the door that says we tried to deliver but your not home. Now my parts sit lonely down the street in a dark warehouse until tomorrow. Poor lonely parts. All alone out there in the world. I need you parts. Come home to me.

[willisbr]

Got some angle and bar in this week. Going to redo some brackets, a rudder pedal, and make a deposit into the bucket of shame toniggt. I still have a left rudder pedal for sale... :)

[willisbr]

I spent the last two nights cutting, sanding, and polishing some new brackets. Finished the rudder pedals. I now have pedals for BOTH feet :)

I'm remaking the suspension forward strut brackets because I was not pleased with my alignment. Ever since I got some better drill bits I have had no problems with alignment. Tonight I will be finishing these last brackets pictured.

Enjoy the pics. Going out for some Mexican. Good night.

[choppergabor]

Having a pedal for each foot is sooooo over rated! Good job buddy looking good :)

[Redbaron]

yeah especially when ur cruising, they seem to help when your takin off tho. :p lookin good brian.

Having a pedal for each foot is sooooo over rated! Good job buddy looking good :)

[willisbr]

Just had my rotors and prop ordered. Decided on 23' Dragon Wings and a Warp Drive. Throw in some purple stuff! :)

[Resasi]

All of those sound like good choices Brian.

[Dirtydog]

willisbr :
I can say it fun to polish that aluminum seem like you can never get is just right. Bad thing is it doesn't stay that way for long. That is the part I hate...
I need to try some of the purple stuff that everyone talks about so much....
Look like your getting there...Great job..!

[StanFoster]

Brian- You will love using Purple polish on your blades. I just re apply some Purple whenever the bugs get to thick on my blades. I can go all winter without need for polishing my blades. Too many people get impatient preparing the aluminum. You can just apply Purple to your blades and start power buffing. It will come out shiny, but it won't have the depth and a true mirror finish if you apply lots of elbow grease first. The aluminum needs to be sanded to finer and finer grades, going down to 800 to 1000 grit. In my case, I had 16 root doubler plates that had to be progressively hand sanded to finer and finer grit. Then, getting a wool bonnet random orbit power buffer and applying liberal amounts of Purple. You must make sure you.are only warming the blades , and not getting them hot. Again, you can have shiny blades by not even sanding them,and just getting instant gratification by applying Purple. There is a difference however. You have to really work at the sanding part to really get a deep mirror shine. If anyone wants to see proof in person, I can show them at Mentone where I did not progessive sand my aluminum, and just used Purple only. Both are shiny, but my blades you can tell there is more depth to the mirror shine. Stan

[Dirtydog]

StanFoster : Not sure if it matters what part of the country you live in, like SC here lot of salt air being 3 mile from salt water.

[StanFoster]

Chris- No doubt you would have to maintain the aluminum more often. I dont have any experience with how bad salt spray is....but that Purple will cut through anything.

Brian.....excuse me, I didnt mean to cut into your build thread. I could start another thread just for polishing aluminum if someone wants. I have seen a lot of mirror finished in aluminum over the years, and asking how it was done has accumulated in my head.

Stan

[willisbr]

I appreciate the talk right here stan. I'm taking note! Thanks for the info. Do DW come semi shiny?

[StanFoster]

Brian- Ernies blades come as nice as anyones. Like I mentioned....you could just go get a random orbit power buffer, and make them very shiny........but........my advice is to convince yourself with a scrap of aluminum. Put some Purple on it only....buff it ....it will be shiny like a new dime. However, start sanding another piece with 220 grit...then 320...then 400.....on down to 800. In all honesty....I really believe you cant tell any difference after 400 grit.

Then power buff this with Purple....and hold them together looking very closely. From a distance...both look the same....but stick your face in there like you are going to use them to shave with. The progressive sanded one will have a deep mirror shine that once you see it....you wont be satisfied with the other one. Whats happening is that the unsanded one is not having all the micro grooves...scratches...etc taken down to a fine and flat level.....and you end up polishing in lots of imperfections. You have a very shiny surface that is reflecting shiny imperfections.

Now, lets say I was trying to polish the mirror for the Hubble space telescope. My finish would be a total disaster, and would not even come close for being a proper mirror, as now we are talking polishing this down to many more stages of finer and finer and finer grits....even getting into liquid grits that go finer and finer.

My point is you get out of something whatever you put into it....usually, but there are practical limits and I feel anything finer that 1000 grit is not practical for just looking at a rotor blade. Maybe some consider the extent I went to as being overkill, but everytime I look at my rotorblades closely, I am rewarded back for the many hours it took to get them there.

I read an excellent article in KitPlanes a few years ago about how someone polished and maintained their all aluminum plane. I remember shaking my head just trying to imagine the work that went into it.......and then maintaining it.

I was correct on the work going into getting the mirror finish....but the article stated that having a mirror finish is actually easier to maintain than a shiny surface that didnt have all the imperfections sanded out. That made a lot of sense to me.....less microscopic nooks and crannies to have the surface corrosion start on.

It wasnt until I experienced maintaining my own blades did I believe that. I can honestly say that maintaining my rotor blades is very easy. I can go all winter with one polishing....and during the buggy season......I can fly for two weeks, and have bugs all over....and it will take at the most 10 minutes of applying Purple with a micro fibre towel to get each blade back to a mirror.

Just trying to pass on information that I had to dig very hard for.

Dont take this as trying to tell you what to do.......I am just wanting to see everyones blades the mirrors they can be.

Stan

[willisbr]

Stan I really appreciate you taking the time in explaining that. I am a novice at metalwork. Cutting, drilling, and polishing. Learning as I go. I will heed your experience and advice. I have seen some rotors at Bensen days that looked like I could eat off of them. Mike's misfitt and that USA scorpion comes to mind.

What are the flight consequences of super polished blades? I've been told to not wax my RAF blades as they will slip more in flight. What of polished aluminum blades? You fly with a high rotor rpm also. No problem?

[StanFoster]

Brian- I love the way my blades fly. I feel the smoother they are, the better, but thats just my opinion. I waxed my RAF blades and my SparrowHawk blades. That made the bugs easier to remove. I would experiment and fly them so buggy, just to see if I could tell the difference. It could have been my imagination...but cleaner blades should fly better...and they felt like they did. I can verify that one time I cleaned just one dirty blade...and flew with a clean one and a dirty one. I could feel quite a bit of shake in the rotor. I am sure I moved enough grams of bug guts to throw the balance off...plus the clean blade had to have better airflow. I cleaned the other blade and it flew smooth then.

While I was building my Helicycle...I was on the fence about should I polish them...or paint them....polish or paint...polish or paint........

I was at Homer Bells fly-in where a bunch of Helicycles show up each year. There was an older guy there named Hap Miller....nicest guy you will ever run across. He had beautiful...georgous polished rotor blades on his. He actually went to Osh Kosh the following week and wont the bronze rotorcraft award...."Liddy" award ? or something like that. Just a georgous ship throughout. He is a mentor of mine and I talk to him by phone occasionally. When I talked to him about his polished blades, two things sold me on going polished. They are just very nice looking...and they wont go out of balance from the paint wearing off. My mind was made up and I went home knowing I was going to polish my blades.

I have seen the Mikes blades. He obviously would be a great one to ask how he did it. I would love to compare notes myself. There are shiny blades, and there are deep shiny blades.

Stan

I will say that once my blades were balanced....I dont have to ever worry about them going out of balance like the ones that painted their blades have happen. No worry of paint eroding from rain etc.

[Penguin]

Ahem. The secret to Mike's MissFit's blade polish is this ... he has his brother polish them! Which is a really good deal. Except when you're the brother.

Before Bensen Days, I polished his rotor on sawhorses with a variable speed buffer and a soft pad. Unable to afford the Purple Stuff, I use a commercial cleaner/polish intended for clear coat. It's readily available from a variety of manufacturers at your local auto paint shop. Since it's intended for clear coats, it's not too aggressive. Do it outside and far from everything. You WILL make a mess.

I did his other brightwork with Mother's Aluminum Polish. I takes tons of rags but does a pretty good job.

What did all this polishing teach me? Well, let me just say that I bought a gyro that is all painted except for the rotor.

[StanFoster]

Larry- You did a beautiful job on the aluminum on Misfit. Georgous.....you know what you are doing.


I also would have polished blades and a painted or preferably, a powed coated frame. That would be a lot of high maintenance maintaining all that aluminum at all the intersections...around bolts...clamps...hoses...etc. Rotor blades are free and clear and the simplest area to polish and keep polished.

I have no experience using Mothers products...but seeing your results...I am convinced that Purple is NOT the only way to go. It just happened to be the product I first used and was delighted with. I am now a loyal Purple fan forever. But had I used Mothers....I would have been shouting Mothers from the rooftops as well!

Beautiful finish work on that Misfit. My hats off to you and Mike on that creation.

Stan

[willisbr]

Good call on the Mother's, Larry! That stuff is great.

[Vance]

I wanted to thank you for this informative thread.

I follow it closely and it adds to my understanding of how an aircraft comes together.

I find your desire to push forward into the unknown territory inspirational and your pragmatic approach admirable.

Thank you, Vance

[Timchick]

The next best thing to having a brother polish your blades is to have Ernie's polisher polish them. He was at Bensen Days a couple years ago polishing blades for a small fee. Money well spent.

[willisbr]

Tim is coming over tomorrow to check out the place and go for a flight. :)

[willisbr]

Well Tim came over last week and put a second set of forum eyes on the Gulf Coast Genesis. He gave me an idea of how to more accurately drill the rudder support tube holes and is letting me borrow a laser and jig. So I'll give it another go sometime later this week. I also was able to pawn off a spring loaded punch to him. I had lost mine and as it always goes, the minute you buy the replacement, you find the lost one.

Nothing new in the shop. I've been reading a bit about Gary's reaming questions. I don't have a reamer and probably won't do any reaming. Many seem to have used this technique. I'm getting very snug (mallet tapper) fits with my Dewalt bits. As soon as I break the hole, I stop and finish the job with a multi-bit. Getting good results. I think my multi-bit is slightly undersized so this has been working well for me.

Nicolas had let me know of a terrible explosion over in Cyprus that had set back some shipping from the shop. I looked it up online and there it was, front and center...massive military explosion that led to numerous casualties. Sorrow goes out to those involved and the locals effected.

My prop is in the mail and I should be getting an invoice any day now from Ernie for the rotors...cough cough.

[willisbr]

I ordered my rotors yesterday from Earnie and they should be here within 2 weeks. I got my prop in about 2 weeks ago from warp drive. I haven't been in the shop much. I sat down and came up with a few concepts for the panel. Here is the digital idea I came up with. Comments?

http://www.rotaryforum.com/forum/attachment.php?attachmentid=83702&d=1313122884

[GaryMac]

Wow, Brian. Either that is really good photoshop, or you have already built your panel. I like it.... how reachable do you think the radio knobs will be?

I'm leaning towards building a larger side console to put the radio, and most other things that I will need to push, and just having flight instruments in the main panel in front. But then again, I'm planning on having shoulder straps.

[willisbr]

Here's the more expensive panel. My dad works on glass all day so he's of course pushing me into higher end. Screw it. Here's the other idea...

http://www.rotaryforum.com/forum/attachment.php?attachmentid=83703&stc=1&d=1313125513

[willisbr]

I'm planning on having shoulder straps.

I like your shoulder straps idea. I'll have to give the lap belt a go a few times and see how I like. Remembering the seat has a nice reclined bucket feel anyway.

[PW_Plack]

If you go with the all-in-one glass, I'd move the radio and transponder up. Looks like a good bit of "heads-down" would be required with them both between your knees.

[willisbr]

If you go with the all-in-one glass, I'd move the radio and transponder up. Looks like a good bit of "heads-down" would be required with them both between your knees.

Maybe like a left and right side kinda deal? The nice thing about this EFIS is that you can control the radio frequencies with certain radio models.

[GaryMac]

If you go with the MGL glass panel, they make a nice radio unit that slaves to the Enigma.... makes it real easy for frequency setting based on a drop down list of nearest airfields.

If cost was not an issue, that's what I was going to do.

[willisbr]

I got my rotors in today. Did an inventory and stroked them a little bit. They sure are nice. Thanks RFD!

[GaryMac]

Sweet!! What size did you get? Did you get the regular blades, or go with the tip-weighted "cruizer" blades?

[willisbr]

I got the 23" and I couldn't tell you if they are tip weighted or not. I remember asking Nicolas about this but forgot what we decided. He placed my order. Went ahead and got me some Purple Polish and some fine grit. Going to take Stan's advice and give it a nice spit n grit shine.

[Aviomania]

Standard blades. Gary when you are close and we have the weight of your gyro with HKS i will order the suitable blades from Ernie and you will arrange the rest with him.

[MikeBoyette]

All Dragon Wings are tip weighted. The "Cruiser Blades" have heavier tip weights in them. This gives them more inertia and makes them more suited for flying staight and level. They fly faster and plow through rough air better.

[willisbr]

So did I want these in this application? I think we decided to go standard because of my weight and sport flight desires. Comment.

[choppergabor]

Looking sweet. I can't wait for you to get airborn and report back to us your experience :) I love the glass.....wow super sweet. :)

[Aviomania]

You are building a fun machine... so standard blades (standard tip weight). Also very nice cruise handling. Depending on the weight of the machine and pilot you will use 23 or 24.

If you built it as it was designed ( no extra unnecessary weight) the 23' are the best. Extra weight on the tips will reduce the "sport" handling a little.

[willisbr]

A few pics of the hood.

[Timchick]

So did I want these in this application? I think we decided to go standard because of my weight and sport flight desires. Comment.

I had Dragon Wings on my KB-2 and never had any complaints. My KB-2 flew nice and sporty.

[willisbr]

Son of a bitch.

[choppergabor]

Bummer!.............

[willisbr]

I got a few things done in the shop tonight. I installed the suspension springs and the rudder pedals. I haven't mounted the seat yet because I'm waiting on my fuel tank. I ordered the largest one and it should be here soon. I'm still planning my panel. I think I'm going to do something simple and not go with an expensive panel. I have my eyes on a Maule bush plane so I'll stick to the lighter is better plan. Here are a few shots of dad and I in the shop. Good night.

[willisbr]

Received the horizontal and rudder components tonight.

[Penguin]

Hey, Brian!
You can't drop out for 3 months and then reappear without an explanation.
Whats the haps?

[GyrOZprey]

Hay Brian,
How big is your seat tank!?
Where did you order it from?
Cost??



I got a few things done in the shop tonight. I installed the suspension springs and the rudder pedals. I haven't mounted the seat yet because I'm waiting on my fuel tank. I ordered the largest one and it should be here soon. I'm still planning my panel. I think I'm going to do something simple and not go with an expensive panel. I have my eyes on a Maule bush plane so I'll stick to the lighter is better plan. Here are a few shots of dad and I in the shop. Good night.

[willisbr]

Hey, Brian!
You can't drop out for 3 months and then reappear without an explanation.
Whats the haps?

I've been waiting on parts, many shipping hurdles, etc.

Oh...and this is where I've been: http://www.rotaryforum.com/forum/showthread.php?t=32422

So I haven't been bored :)