My AC Tandem Jungle Jet Flies Again With 165 Rockin Horses!

[fiveboy]

I have logged on to this forum just once in over a year. So why I am logged on for this post? To share something uplifting (pun).

Minnesota Mike made me a promise that he kept. He promised me that he would help me get back into the air after a debacle that bled a year out of my flying career and left me Shanghaied here in Panama with few real options.

Without going into the play by play of the build (which I intend to write up for the PRA online magazine) - I got a used Subaru 2.5 - had it custom rebuilt and beefed up at CCR rebuilders in Colorado and shipped it here (Panama). Mike then came down for three months and lived in Spartan conditions. Every day for 45 days we slaved like dogs in an environment that would be hellish on a good day. Cold drinking water was our greatest luxury. Limited to essentially files, aircraft grade aluminum (that Mike calculated and brought along) - a drill press that I bought, a hacksaw and a collection of AN bolts, and clever re-purposing of what pre-existed on the machine -- he masterminded a rebuild that is nothing short of incredible. His background as a Master Jeweler came through at every turn. Many was the time I would say - "It looks fine- stop obsessing we need to keep going!" and he would still bevel edges, round off cuts, polish and fit with amazing skill, precision and effort - and stunning effect. All of the wiring was redone (that was my primary area) and a new instrument pod installed (weird but cool to be using automotive stuff!).

We drove an hour each way each day (and you haven't lived until you drive in the traffic here and then go into the back country and dodge the semis barreling at you on single lane roads at waaay too fast!) - work a full 8 hours - only to return the next day - day after day. Last time he was here it was all booze and trim. This time was all deploy and execute.

If it didnt exist - he somehow fabricated it. Prerotator mount, radiator mount, adapter for a starter that didnt quite fit - on and on. We spend almost whole days some days just sourcing the tiniest things that you guys go to the local mall to get in ten minutes (like a radiator cap!!).

But as of yesterday - after listening (as I always do) to my CFI and constant coach Chris Burgess, and taking it really slow and relearning all the new weights and balances and performance characteristics on the ground in high speed run ups - I finally flew her off the earth and it felt great!

Not to be missed is the patience and ever present good natured help of Don Parham who rewired the harness. Once I got past a certain psychological impairment in reading his clear schematics - it was literally plug and play. Don was there by phone and email every step of the way - even shipping me a different starter with the correct throw for the bendix. His idea of "customer service" is old school and a delight. A real and knowledgeable pro.

I have enough hours of ground practice now to be past the break in point of the engine.... so its all blue sky from this point onward.

As for Mike and his contributions to this project - there are not enough words to praise or thank the man. All I can say is two guys working where and how we did - who didn't rip each others throats out (maybe we wanted to but we didnt!) is a testament to problem solving, dedication and.... true best friend ship.

I am posting just a few pics for the curious.

If you want to offer congrats - thanks in advance. If you want to start nit picking and chest puffing - I wont be logging on again to see either in any case. For me this forum is for informational purposes only on an as needed basis. The politics, cult of personality, and schoolyard bullying drove me off for good.

Im sure Mike can handle any info for those who truly want to learn anything from our experience. To the perennial naysayers, debunkers, nabobs of negativism I'm hoping he will ignore you as I have learned to.

Thanks Mike - I am flying again and working alongside you was like taking a Masters class in innovation and aplomb. (And cool under fire has a new meaning since the day we worked right through the airport being totally on fire! loL).

Safe Flying All
Ad Astra

Rob

PS Yes the wiring looks sloppy because its the lay up - it is currently being cleaned up now that I know it works and the bogeys have been hunted down and eliminated.

[StanFoster]

Rob- This is great news. Mike gave me a sneak peak, and I was amazed at all the work the two of you pulled off. Enjoy flying it, you deserve it. Looking forward to your article. Stan

[Minnesota_Mike]

I thank my very good friend Robert for his kind words.
All he said is true...including the airport being on fire (like all the grass everywhere!!!!!...they burn it down instead of mowing).
That afternoon it looked like hell on earth.

The challenge was to pull this project off in the short time frame we had...with very limited resources and supplies- all on the edge of the Jungles in the interior of Panama.

We brought in all the 6061-T6 we needed (can't find it in Panama) with the engine and all associated parts.

The spartan conditions of our work environment...as well as my low-tech work station (below) is proof to the fact that with careful determination and the simplest of tools One can produce results.

The canister style exhaust design was suggested by Chuck Freese, President of PRA Chapter 17 MN. ...and it is amazing...!
(Thank You Chuck..!)
The circular flow design is astoundingly quiet with great flow through, and nearly the only sound you hear is the Prop...!!!

Hear it run (during break in) at barely 1/3 of it's potential RPM capability with this video.
(...a little choppy from a Quicktime format which does not convert well at the Vimeo site.
Let it cache fully which aids in playback).
Soob 2.5L Engine Conversion on an AirCommand Tandem Gyroplane on Vimeo

All in all, it was an exciting and rewarding process for both of us that required total commitment and teamwork to bring it to completion.

M-M.

[Vance]

That sounds like quite an adventure.

How much more did the Subaru engine, re-drive and exhaust weigh compared to the Hirth?

Did you have to change the rotor head location because of the extra weight out back?

Did you move the mains because of the extra weight out back?

How did she hang?

How does she fly?

Thank you, Vance

[Resasi]

Mike since you will be in contact with Robert, please tell him he will be missed by those of us who enjoyed his presence on the Forum, and I was one.

Well done to the two of you, it is always uplifting news when someone gets grounded in less than ideal conditions and wins through and it sounds as though you had quite a lot to do with that.

Always good to hear of a grounded aviator getting up into the air again. Been there done that... a couple of times and I know just how good it feels when it happens.

[Minnesota_Mike]

Answers to your questions Vance...

How much more did the Subaru engine, re-drive and exhaust weigh compared to the Hirth?

I do not have the exact numbers in front of me (they are in Panama w/ Rob)...but I can say without exception that is was an easy 190Lbs

Did you have to change the rotor head location because of the extra weight out back?

Yes, new cheek plates were constructed and the head was moved back considering the added weight.

Did you move the mains because of the extra weight out back?

Conversions completed by others we conferred with (on the same make airframe/type of engine build) have been with and without moving the mains.
We located the Battery in the nose cone and on that long moment arm it made a huge difference possibly voiding the need to move the mains.
We opted to take a "wait and see".

How did she hang?

We performed a Hang and then a balance (on blocks under the mains) and found that the balance was dead on.
No change from the original "stock" CG.
(See photo below).

How does she fly?

It is flying and handling quite well Rob tells me.
He is a patient and "by the book" Pilot, who will continue to progress slowly with the acclimation process.
Robert has been slowly pacing himself through a "reorientation" in a now completely different and much heavier machine.
The big difference he remarked is how it feels in handling with the additional mass...but it's far from unmanageable...and he tells me the amount of thrust (compared to the Hirth) is like night & day.
(The word "screamer" comes to mind).
The blades will not at this time support flight with a passenger (since the added engine weight gobbled up that capacity).
In time I'm guessing that new blades will be installed to regain that payload capacity.

M-M.

(Thanks Leigh...PM your contact Info and I can pass it on to him..or simply Skype him).

[rfonseca]

Nice to know that you have already finished, Robert and mike. Blue skies and happy landings!

[Timchick]

Congratulations!

[Minnesota_Mike]

Thank You Ramon.

Thank you Tim.

Thank You Stan...having been with Soob in the past...you know how nice they can be and their downsides too.
(But now...have Kerosene...will travel...eh..? Lol...<smile>)

We have some small changes in mind to dial this in better...but for the most part it is good to go.
Looking now in to ECU Maps and reprogramming
(Thanks Larry <Lanicol>...great food for thought).

M-M.

[RotoPlane]

This operation definitely shows that where there is a will….there is a way! You guys should be very proud of this neat machine. I have missed Rob's witty posts….

[ckurz7000]

Reads like a real life adventure with a happy end. Thanks for letting us in on its happy end.

-- Chris.

[Minnesota_Mike]

Thank You Ed & Chris.
In Panama every day is a real adventure...seriously.

[Minnesota_Mike]

I was extremely excited to see this video today...being that it is the culmination of much hard work while in Panama.
I hated to return so soon to Minnesota not being able to witness this event first hand, but such is life.

I'm sharing it here for all to enjoy.

M-M.

Jungle Jet-First Pattern Flight= MAY 22 2011 on Vimeo
(I wish I could have filmed this while there because I would have made sure to to get better views and more of them..oh well, I'm still elated).

[Riff Raf]

Which re drive is that?

The whole install looks real clean on the Jungle Jet.
Very nice.

[Minnesota_Mike]

Thank you for your kind remarks Roger.
I pulled this info for you.

http://www.airtrikes.net/engines.shtml

(from the site...)

SPG-4 ....gearing to 3.16 recommended for up to 180HP high torque engines.
German (BMW) rubber damper between the gear box and the engine.
The propeller moment of inertia up to 9,000 kg/cm2.
Rotax-style propeller hub, propeller shaft with a hole so it can be used with variable pitch prop

Offset (dimension between crank and prop shafts) 90mm 3.55"
Propeller hub Rotax standard**
Gearbox weight 8.5kg 18.7Lb
Full conversion kit weight 26.5 Lbs.

My comments:
This is a nice looking unit made in Poland.
It is cast from metal molds and the components are quality grade.
It was specifically re-designed a few years back for high HP engines from previous versions.
After the break in period, it was drained/ cleaned & filled with a synthetic grade lubricant for better lubricity under high temp conditions.

M-M.