Bending 2x2" vs welding

good day friends,
I have decided to go with a different tail on my project (from tall tail to tail boom mounted). With my straight keel, the new tail's h.s. is too close to the ground, therefor I would like to put a jog in the boom to raise the stabilizer. (I've included a picture of what I have in mind). The piece of stock I'm using is 2x2x .125 radius square tube 6063-T5 . I know it will bend ok but will bending take away strength, give it strength or should I just weld it.

Thanks,
Jay

As close as those bends are Jay, I wouldn't try bending them. I believe you would have unacceptable deformation and a great loss of strength at the very small radius curves necessary. Most builders would simply cut the square tubing and put a plate on both sides across the joint for strength. Bolted is common. It also could be bonded and riveted as well. The aluminum would weld, but the heat from welding would cost you the strength of the metal, and no one I know would have the piece solution treated and aged to get it back to its original temper. Most would advise against using 6063 tubing as it is much less strong than 6061-T6 at the same weight and cost. Is there some reason you are using 6063? If you want radius corner tubing, you can get it in 6061-T6 at Online Metals. https://www.onlinemetals.com/
6063-T4 is 25,000 psi Tensile strength 13,000 Yield
6061-T6 is 45,000 psi Tensile strength 40,000 Yield

Thank You John,
That is why I come here, I always learn something to make building safer and more fun.
Just ordered 7' of 6061 t6 from OLM

I will answer an unasked question.

The tall vertical stabilizer/rudder is to reduce power yaw coupling.

With a short vertical stabilizer/rudder the prop wash that comes off the prop in a circular motion pushes the stabilizer to one side resulting in a change in yaw with a change in power.

This can make landing with power changes more challenging.

I prefer a tall vertical stabilizer/rudder.

Most gyroplanes produced today have a short vertical stabilizer/rudder.

Thanks Vance,
here is a picture of my new tail, I'm pretty sure it will have enough vertical. My tall tail didn't have a horizontal stab, I would have had to make one which isn't a big deal. Also, I didn't like the way the top mount got in the way of my pre-rotator. Plus I want to let it go with the gyro frame I'm going to sell when I finish this one

It isn’t about vertical stabilizer volume; the yaw coupling is about height of the vertical stabilizer.

Again answering an unanswered question; that appears to be a very heavy empennage and it might be helpful to have a stronger keel.

All Rotorcraft shake and if you put something heavy on the end of a stick the stick wants to break somewhere in the middle.

Have a good look at the keel of the gyroplane that typically goes on and try to make your keel as strong.

After looking at the keel this tail came from, I'm really glad you told me to check . I definitely need to beef this puppy up. I believe Paul welds steel maybe stainless, I know his masts are made that way. The tail weighs about 25lbs.

DangerBird said:

After looking at the keel this tail came from, I'm really glad you told me to check . I definitely need to beef this puppy up. I believe Paul welds steel maybe stainless, I know his masts are made that way. The tail weighs about 25lbs.

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I hesitate to answer unasked questions and your response has been gratifying.

Thank you Jay.

The tail you have Jay, looks like a Tango Gyro tail, I'm guessing for a 2 seater. It attaches to a 2"x 2" piece of welded Stainless steel square tubing. For the volume, the weight of the tail is not too bad at all.

Here I go again; have a look at the structure.

It is not simply a piece of 2X2 stainless tubing.

It is braced almost all the way to the propeller.

Follow the load path.

Jazzenjohn said:

The tail you have Jay, looks like a Tango Gyro tail, I'm guessing for a 2 seater. It attaches to a 2"x 2" piece of welded Stainless steel square tubing. For the volume, the weight of the tail is not too bad at all.

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Correct as usual sir

Is it your belief that the brace is there as support for a heavy tail Vance?

Vance said:

Here I go again; have a look at the structure.

It is not simply a piece of 2X2 stainless tubing.

It is braced almost all the way to the propeller.

Follow the load path.

Click to expand...

Vance, I have tons of room to add all kinds of braces as needed to support the boom, I may not even cut it, Sport Copter's tail is on a straight keel. I'm not sure yet. Either way, I will show you guys what I come up with before I do anything and see what you think,
Thanks, You and John have always been helpful

Is this going to be for a single or 2 place gyro Jay? What motor?

This particular build will be a single place, very small 503 just to get me reacquainted with flying (it's been a few years). I was just going to rebuild the gyro I bought last summer, but after buying everything I needed and replacing some tubing, I pretty much have a new gyro. When I bought new pieces, I bought them thinking I could use them on my next build. I do have a question though, after spending a bunch of money on the rotorhead that came with the gyro I bought, I decided I wanted a different one, so I bought an unused RFD 2 place rotorhead, My question is, this isn't too much rotor head for a single place I hope (if there is such a thing)

The only difference I know of is the extra bearing and the height of the teeter towers. I doubt there is more than a few pounds difference although you will need to research the height of the towers. Making different ones is a very simple machining operation.

I us an RFD two bearing head on The Predator with custom made towers.

It has held up well for over two thousand hours and twenty years.

The tail is too big for a single, and both are a bit too heavy for a 503 gyro. This is coming from someone that is often accused of having a tail bigger than necessary. I think a 2 place head on a single place is less of a problem, but you'd first need to check whether the blades you have will work with them. Which blades do you have?

Jazzenjohn said:

The tail is too big for a single, and both are a bit too heavy for a 503 gyro. This is coming from someone that is often accused of having a tail bigger than necessary. I think a 2 place head on a single place is less of a problem, but you'd first need to check whether the blades you have will work with them. Which blades do you have?

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This is going to sound weird but 23 1/2 foot Dragon Wings (custom hub bar). I haven't received the tail yet (en route) so I don't really know what I will do. I still have many options.
Another question, Heat treating 6061 t6 isn't a big deal is it. If not, I could weld up some pretty cool stuff

Unless you are a craftsman I would stay away from welding on an aluminum gyroplane frame.

I second what Vance said concerning welding the structure of an aluminum gyro, even if it were retempered. If you want a welded frame, use 4130 steel.