New Hornet(s) in the works!

[Resasi]

Not so much now, but during training, the brakes on the Bensen were not good. I was a student and had some hairy moments with insufficient stopping power as I had not got used to using the rotor disc. This exacerbated by the fact that without a prerotator I was on the move a lot of the time to keep the rotor spun up.

The brakes on our Hornet are very good and I feel comfortable with that. I also made sure that we had a rotor brake, as with the tall mast the freewheeling rotor was hard to stop and we needed to be able to control it. The Bensen is low enough to stop by hand, but does in fact have a good rotor brake.

It's been a great build log with some lovely work done. Most enjoyable to follow.

[CLS447]

Denis, I do not have the clutch in my C box. I engage my PR at pretty low rpms & slowly increase. With a clutch, the prop would not even be spinning when I engage. I figured it wasn't worth it .

I kept it the way Rotax made it.

I was wondering how hard it would be to twist the 2 carb cables.

Thanks, & keep up the amazing work !

[robo_nipsy]

Deadline is approaching quickly, but getting a lot done...
If I had been working at this pace 2 years ago, I would have been done with my machine 1 3/4 years ago!!

I'm planning on getting a bunch of machining done this weekend.
But in the mean time, here are a few more progress pics...

Continuing on with the pre-rotator drive system.


I started with the shaft support bearing that is located up around the hinge point of the folding mast... (This part was actually completed a couple months ago, but I had to save this pics to go with this sub assembly...)







Then, the 90° gearbox (This was last weekend).....







Yesterday I got my mountain bike brakes mounted! I think they turned out really slick! (Pictures to come later today/ tomorrow)

You guys were right though...Those Azusa wheels are crap...I'll have to do a bunch of shimming to get the brake disks to run true....Oh well. This will be a future upgrade area.

Well, I gotta run and have a picnic lunch with the relatives... Bummer. I would really rather stay here and work on the Hornet!!

I'll have more pics in another couple days...

Denis

[Vance]

I admire the thought that has gone into your prerotator.

Your machined bits, attention to detail, thoughtful design and progress are an inspiration to me.

Thank you, Vance

[Russ Hobbs]

Sling blade, I can here those rotors singing now. Denis, will we see this pre-rotator in action at Mentone. See you there.
Russ

[Resasi]

Dennis a very interesting prerotator.

What does it weigh?

Any idea what rotor rpm you will be expecting to achieve with this?

[HobbyCAD]

Hi Denis,

Where did you source your alu tanks? What P/N's are they?

Regards,

Francois

[RotoPlane]

When I look at these pictures I not only see reasoned design, great CAD work, and machining skill savvy…..I also view art…in flowing metal.

I would be so proud if this were my work….

[GyroDel]

Can't think of anything more to say that hasn't been already said, so WOW!!! Stayed up last night until almost 2 AM reading the entire thread. I can see why so many were wanting more and faster posts to see what happened next. Now I too will be waiting to see what is instore for the next update.

Dennis, you have taken gyro building to a new level, it is amazing. If this is your vision of a build knowing nothing about this sport. I for one can't wait to see what your next build will be after you have got some time flying this beauty.

[robo_nipsy]

Thanks Guys!! You are all way too kind!
I'm having a blast with this and I do enjoy sharing my addiction!

Vance, Thank you!
You have no idea how inspiring all your posts have been to me since I joined this forum! I'm glad I can return a slight fraction of the joy that you have given to this group over the years!
Looking forward to meeting you and listing to your presentation at Mentone!!

Russ,
uuummmmggghhh...I sure like them there french fried pataters...
Yes, I'm sure I'll be able to "spin em up" at Mentone...I am hoping that the machine will see at least a little bit of air at the event (Not by me of course)...I still have a lot to accomplish. We'll see.

Leigh,
Not sure on the exact weight of just the PR system... Haven't taken the time as of yet. I will soon.
The target rrpm output was just a guess on my part.
With the 2.58 on the B box, 1.548 on my belt drive, and 12:1 on the bendix, this will give me 200 rrpm with 4000 at the engine. 6000 on the engine will give me 300.
I guess I'll have to wait and see what my brakes will hold during the spin up.
What do others figure for max engine rpm during spin-up?
I played with my belt drive design and it appears as if it would be fairly easy to tweak some diameters and dial it in once I get a feel for it....

Francois,
The tanks are from http://www.coyote-gear.com/
I'm really happy with them!

Roto,
Thanks! I do take pride in my work. Never considered myself an artist though... I'm just fortunate to have found a sport that makes so good use of my "nitch".

Del,
Thank you sir! yes, I am excited for my next projects! I know I am hooked on this for the rest of my life!
But, I promised the wife that I would not immediately start the next one....I'll have to give it a rest for a couple months!! :-)
She has been so great and understanding!! I owe her a lot for putting up with my addiction!
I need to take care of a least a couple items on her honey-do list!

Besides, I need to get trained, and then get some air time in this thing so that I can see what I do and don't like about it... Then I'll have a clearer direction for my "next" one!!

A couple quick pictures ....
Here is an overview of the mountain bike brakes I put on...
As usual, please disregard the temporary bolts.....Just for fitting purposes only.






The plastic wheels are no where near true...I'll have to adjust the stand off posts to get the disks to spin true.. I think they are going to work pretty good though.
I have not decided if I am going to keep the independent braking or combine it into one control handle.. (Not sure exactly where I'm going to mount that either)

I made new cluster plates for this axle group. I needed to cut away to top outer edge of the plates to make room for the disks.
I increased the plates from 1/8" to 3/16" thick to maintain the strength here..


Here are some more parts for the rotor head and bendix mount.



I've re-built my rotor head as well...My old one used needle bearings...I put DU bushings in this one....Several reasons, but I'll discuss that later..
Actually TU bushings...Same thing, just different manufacturer...

You can see the plastic inserts I have for my teeter stops. These are taller than they need to be.
I was going to hang my blades on again tonight, but I'm getting too tired..Maybe tomorrow.
I'll then trim these down to allow as much teeter as possible (at least 9°) but not so much that the blade could possibly strike my tail.
Hopefully tomorrow I can post a pic of it all together.

Cheers,
d

[Resasi]

D you are doing great.

I love just dropping by and getting an eyeful of gyro eye candy.

[robo_nipsy]

Hey everybody!!

Sorry for the lapse in my update pictures!

The days/weeks leading up to Mentone were more than a little hectic!
I just simply did not have a extra minute to sit down and post anything let alone take many pictures.....But I will fix that soon!

Expect to see some more posts from me within the next week or so after I get caught up a bit here at work.
I have so much to write and share!!

I have so many people to thank and compliment for such a wonderful time at Mentone!!

All I can say right now is WOW!!!!
I was so impressed with all the people in the PRA! What a great group!

I need to write so much more because I need to thank so many people and I don't want to leave anyone out!

Yes, I was honored so very much to receive not 1, but 2 awards for my machine at the event!

As I said, I have so very much more to write, and promise to get more machine progress pictures out to you all soon!



Saturday Morning, August 4th, about 7:30 AM, at the PRA's 50th anniversary, Mentone IN..........Fellow chapter 17 (Minnesota) member Paul Minear and I, rolled my gyro out past the flight line to the other side of the runway and secured the tail boom to the red concrete post.

With a big smile, I spoke the words "Clear Prop"

With a few pulls on the starter cord to get fuel up to the carbs, the engine started to sputter...A few more and it came to life for the first time! Since the engine had not been broken in as of yet, I kept it at just a little over an idle......

I sat down in the seat and engaged the prerotator. With a short little "chirp" of the fresh new belt the blades began to turn! So quiet, so magical!!

What a great feeling!

I will leave you now with a couple pictures of a VERY happy guy and his machine!!

I will be writing again soon to sing more praises of the PRA and ALL of it's members!

Thank you everybody!! Thank you, Thank you, Thank you!!!!





Look at that smile on that guys face!!!

Thanks again everybody!!!
We'll talk soon!

Denis

[StanFoster]

Denis- I never got to talk to you at Mentone...but your machine was a piece of eye candy. I wish I had your vision and machining skills. Amazing detail and beautifully done with finesse. You earned and deserved every award.


Stan

[Resasi]

Dennis so very pleased for you, awards well deserved. Glad you enjoyed yourself there.

Many of us on the Forum have avidly followed your progress, aided by the wonderful photos you have been posting. It is such a great pleasure for people to be able to see what gifted craftsmen like you, and others on the forum, can produce.

Please don't stop, keep us up with your journey to get this beautiful piece of art into the sky, and how you get on with your training.

Plenty of questions still for you to answer at some stage, what was her final empty weight, what performance you get with your prerotator, thrust figures, when you get the engine run in.

Looking forward to all these and more, and hoping you will keep us with you on the journey.

[Thechap]

Dennis,

Don't forget what we spoke about. Radio holder? Let me know what you figured out. By the way, once again, you did a beautiful job on your Gyro!

Bryan