Jonathan
I discover Neil has used only the flex plate from an automatic application to use as the coupler to bolt the rubber coupler to.
The area in improving the AeroFlight 33 was to have a serious look at the configuration you mention above, using a flywheel with a low mass moment of inertia will undoubtedly create what is called torsional vibrations. We have eliminated this by delivering this particular box with a proprietary engine coupling system, which typically consists of an engine specific weight pressure oil filled flywheel, the starter gear, and in between the flywheel and box we have a Centaflex rubber coupling connected to a splined hub, and splined shafts connecting to the gearbox. The improved coupling system removes over 99% of all engine torsional pulses which the engine produces at takeoff and cruise power, and provides the propeller with an operating environment which is essentially devoid of engine torsional excitation. The company will not sell the box without the above. The box is sealed, any attempt to repair the box other than authorized personnel will devoid of the warranties.
What materials are the shafts made out of ? To what rockwell number are they treated to ?
All gears are manufactures according to Gitin M Maitra specification and Case Carburizing to HRC 55-60 and of the core around 30-40, the original gears somehow had not the correct tip circle,root circle, addendum, flankl of tooth, ect, they were all redesigned and the box is delivered with matching gear pair. All gears at chemically etched, with date of manufacturing, machine operator and box destination. Gears are mass manufactured by VW-china. Boxes are made from 3xx.x series alloy and T-6 tempered, all castings are made by FAW Group Corporation, and makers of gearboxes for the US automotive companies.
As far as a free one, I would be willing to put one on the dyno to see what it does but that will not duplicate the gyroscopic forces during a real flight test, etc.
Good news are the AeroFlight 33 has been in trail service since Feb 2008 and currently in operations with a Shandong aircraft maker in training aircrafts with over 4000hr in flight service with a Subaru EJ225 N/A VTC detuned to 190Hp engine and a 3 blade electric MT -CS propeller with electric governor.
There is a huge market in China for aviation reduction boxes for the Chinese aircraft industries, being made in China, the boxes must have not equal but better standards of to pass Chinese Airworthy Certification and unknown to many experimental aircraft builders in the US that in accordance with the U.S./People’s Republic of China Bilateral Airworthiness Agreement and the associated Schedule of Implementation Procedures, airworthiness certification of aeronautical products is reciprocally accepted.
Thank you for your attention
Albert