RAF aluminum replacement tank PRA Ed kit progress

All_In

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This is one of 12 PRA ed kits we have sponsored now at 3 colleges with now the MM & EE departments. No more leaks forever!
You will be able to buy PRA educationals kits including all engineering data, SolidWorks drawing, CNC code, software, circuit board schematics etc. SOON!

You will also be able to buy the tank built and the rest of the parts from Rotorland USA, who buys the Ed kit from PRA for each customer for you and sells you the parts to complete the kits in a quick-build educational kit.

Here is the latest report for TEAM RAF-Fuel System with a fuel totalizer gauge.

Professor,

Here is our 7th weekly update. Let me know if you need anything else.

  • Project Name: Rotary Air Force 2000 gyroplane fuel system safety redesign
  • Project Sponsor: PRA
  • Weekly Status Report Date: 3/6/2020
  • Project Number: 13, Team Number: F10
  • Team Members: Cody Rahders, Steven Parker, Francisco Carvajal, Mike Chiavacci

  1. Key Accomplishments

Back Panels Welded
Fuel Box
The fuel box has been built and riveted together. Rivet nuts were also added. The exterior was sanded and swirl marks were added for a more attractive appearance.
PCB
The PCB schematics are completed. A 3/D model has been rendered to show the final product. For assembly, there will only need to be some solder time.
Issues
With the fuel box, there are a few interference due to the rivets after they were deformed. It's believed they can be sanded and the interference will be relieved.
Growing concerns on the external fuel tank might call for a SRD change with the appropriate paperwork to get signed off.

  1. Schedule Performance
Welding tank
Fuel Box Assembly
With the box built, components can be added to the box so it will be ready to mount to the gyrocopter.
Meet with John test the transducer
The team meets with john on Tuesday to test the transducer.
Get PCB to manufacture
The team will send the PCB to be manufactured once the code is confirmed done.

Thank you,

Cody Rahders
 

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All_In

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Piper Archer, Aviomania G1sb
Total Flight Time
Not sure over 10,000+ logged FW, 260+ ultralights, sailplane, hang-gliders
Description of Project for Popular Rotorcraft Association's EDUCATIONAL KITS,
1) Two-speed transmission car stater prerotator. 29' blades to 150RPM.
2) G-Impact Fuel cut off switch. WORKS GREAT.
3) State-of-the-art electric highspeed prerotator. In testing want 29' 220RRPM.
4) Height AGL display instrument. A spinoff, of two projects, have lidar sensors so, might as well display it. This is an option for kit #2 and kit #5.
5) Anti-Tip-Over stop and drop landing gear
6) Jump-Take-off 1st 3/4.of the project.
7) Fuel-Flow Totalizer instrument.
8) Yamaha 85HP Engine with internally geared redrive (This is not be released for one year. Allow that time for Greg Mills to develop one for our community)
9) RAF aluminum fuel tank replacements without the new fuel system.
10) RAF the new fuel system.
11) Stronger RAF pre-rotator Bendix housing that you attach the flex shaft. Thicker and curved radius, no cracks.
12) KB2, by itself, have drawing /plans made
KB2, with the anti-tip-over landing gear
KB2, with jump-takeoff
KB2, with all the improvements above
13) CheapSpin = Improve Car starter Prerotator with a two-speed transmission. With drawings.
14) HighTwister = Prerotator = Correct the problems with gears clashing and improve Rotor RPM’s - highspeed state of the art electric pre-rotator
15) InCaseIt = We have at least 4 or 5 projects that require weatherproof and professional-looking instrument boxes
16) UltimateFrisbee = Vertical take-off/hovercraft Frisbee. Been wanting to do this since they first came out. We cut the disk into rotor-blades that can pull both positive and negative collective. It becomes a hovercraft to taxi. Then sits down on it landing gear and set the disk to zero pitch. (smooth disk) spin the disk up to 1,000 RRPM and pull collective. It can be driven by either eclectic or the jet engine off of jet’s bleed air system through the collective tubes exhaust outlets at the disk ends that spins the disk. You maneuver by ever so slightly adding and substracting collective to only two blades as they hit the 3 and 9 o’clock position like wings/rotors.
 

All_In

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Joined
Apr 21, 2008
Messages
15,204
Location
San Diego, CA. USA
Aircraft
Piper Archer, Aviomania G1sb
Total Flight Time
Not sure over 10,000+ logged FW, 260+ ultralights, sailplane, hang-gliders
This PRA educational kit is almost finished. After seniors graduate in June PRA will provide these as DIY kits.
IMG_3779.jpgIMG_3710.jpgIMG_3780.jpg
 

All_In

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Piper Archer, Aviomania G1sb
Total Flight Time
Not sure over 10,000+ logged FW, 260+ ultralights, sailplane, hang-gliders
The sad news. It appears this is the only project that will be finished. S.D.S.U. and S.D.U. has shut down their machine shops. So unless they open by 4/12 no hope of finishing this semester. Some projects are printing 3-D plastic parts for those parts not machined. That is all they have left.
Bummer, nothing can be easy?
 

Gyrob

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I was checking back to see how progress has been coming on these projects. Bummer on shutting down the machine shop, but I was interested if you still think the fuel tank project will be completed?
I am looking to get my old style tank replaced and interested in this project.
Thank You
 

All_In

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Joined
Apr 21, 2008
Messages
15,204
Location
San Diego, CA. USA
Aircraft
Piper Archer, Aviomania G1sb
Total Flight Time
Not sure over 10,000+ logged FW, 260+ ultralights, sailplane, hang-gliders
We are searching for machine shops to make the parts now.
Or if you wish to make you own all of the design instructions are included in the PRA Ed kit.
I'm setting up a need separate from PRA LLC corporation called RotorLand in NV that will sell parts or complete finished projects,
This is for liability reasons. However, Rotorland buys the Ed kits from PRA and includes in the price so all will be buying PRA Ed kit one way or another.
This will assure that PRA Ed kits are self-sustaining and allow PRA to pay for many more projects for the good of our community.
There is an Ed kit in the works to convert an RAF adding a Lycombing O320 150HP certified aircraft engine you can buy with 1/2 time for about 5K.
 

okikuma

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May 21, 2006
Messages
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Location
Santa Clarita, CA
Morning John,

I wonder if using an O-320 is a bit of overkill as in weight, horsepower and amount of torque at the prop. There is a much lighter solution.

Sometime back on this forum, I saw a video of an RAF-2000 with a Continental O-200 and then posted my comments and ideas.

Here it is:



I just re-read my previous comments back in 2009 with the Continental Powered RAF-2000 that I will cut and past here:

"like the idea of using the O-200. I've ran this idea through my head many times prior and wondered if it would be worth it.

As it looks in the video, the O-200 setup can't weigh more than 250 lb. total including prop, prerotator, and oil cooler. Install a Sparrowhawk drop keel mod and it would be a great machine to fly.

I'm sure with this setup, the O-200 RAF could easily have a declared gross weight of 1320 lb and still have a 600 lb useful load (720 lb empty). With the decreased empty weight, I'm sure the 100 hp will perform very close to the higher weight 2.2L Subaru installation.

The O-200 will run on 80 octane so auto fuel can be used. There's also a high compression version (not the O-240 that you might be thinking of) that will run on 100LL and produce 125 hp for take off power. I recently saw one of these 125 hp upgrades in an Ercoupe. The owner said that he can cruise at 130 mph with the 125 hp."


I subsequently found out that Continental Powered RAF-2000 was owned by Gillispie "Jimmy" Meredith of Palmyra, Virginia. I was able to telephone Jimmy and we spoke at length about his conversion. Here's what I posted after that conversation:

"Earlier today, I spoke with Gillispie "Jimmy" Meredith about his Continental O-200 powered RAF 2000 gyroplane N2029E.

http://www.vimeo.com/2021802

Jimmy is a great guy to speak with and was very gracious to take the time and answer all my questions about his gyroplane. Thanks Tim for your assistance in locating Jimmy.

As I figured, Jimmy's RAF gyro empty weight is lighter than the equivalent Subaru powered versions. What is surprising is how much lighter. Jimmy tells me that his gyro's current empty weight is just under 620 lb.! That is a significant weight reduction! Here is a two place EAB gyroplane that is LSA compliant and can have a 700 lb. useful load! I forgot to ask Jimmy what is the specific gross weight limit he has set for his gyro.

The Continental engine is really an upgraded C-90 with O-200 crank and pistons. The engine does not have a starter or generator/altenator. Jimmy says he has set 2900 rpm as his max rpm limit and is for take off only. In cruise flight, he operates it between 2400 - 2500 rpm and cruises between 70 - 80 mph. Jimmy says that the cylinder head temps are a cool 325 degrees and oil temps never climb above 160 degrees. For extra insurance, he added an oil cooler and it sits down low and near the prop. The prop he is using is a 68" Warpdrive and says he has measured 430 lb. of static thrust. I mentioned to Jimmy that figure seams low for his gyro. When I said perhaps if he used an IVO prop, he could obtain 600 lb. of static thrust, he agreed and that is in consideration. The two fuel tanks are 5 gallons each for a total of 10 gallons and it is a gravity fuel system. He mentioned that he might add a small header tank down low to increase the capacity. Jimmy is also looking into a wind powered generator for electrical power. I suggested that he look at the Kutoba series of alternators for light weight electrical power.

When asked how well does the gyroplane fly compared to the Subaru powered RAF 2000s, Jimmy says it much easier and feels more stable, even though it is a HTL gyro and has no horizontal stabilizer. I did not ask if he is planning on adding one in the future. He said that he flies the gyro conservatively and most often solo. I asked how was the performance with a passenger and he said it was alright, however he has only flown down the length of the runway with a passenger. After more experimentation and work, he'll then fly a pattern and then a short cross country with a passenger.

When I asked Jimmy why the Continental engine, he said he just feels more comfortable flying behind a certified aircraft engine. He also said that he believes that the initial cost, operating expenses and 1500 TBO life of the engine is still cheaper than setting up, installing with all the associated hardware, water cooled system, PSRU, and maintaining the Subaru.

Doing some quick figuring, Jimmy's gyro with a 200 lb. pilot, full tanks and oil (68 lb.), and with a 30' rotor, the disk loading would be 1.26 lb. per sq. ft. Add a 200 lb. passenger, the disk loading would be a respectable 1.54 lb. per sq. ft. Not bad at all for a two place gyro.

I think Jimmy is moving in the right direction in owning and flying a useful two place gyroplane. Just think what the performance would be with a O-320 Lycoming powered Sparrowhawk?

I invite comments about what Jimmy has done. Those of you out there that want to dwell on how Jimmy's gyro is a HTL aircraft with no horizontal stabilizer, that is not part of the discussion here. I want to concentrate on the benefits or detriments between the use of an air cooled aircraft engine vs. the Subaru."


Interestingly, I did comment on the idea of a O-320 powered Sparrowhawk.

In summation, I think a Continental O-200 powered (or a Rotax 912 for that matter) RAF-2000 would make the airframe substantially lighter, and a better performing gyroplane as compared to using an O-320.

With the upgraded aluminum fuel tank kit, and a Continental O-200 with an Aero Injector carburetor, one could posibally use automotive fuel that perhaps has up to 10% ethanol.

Wayne
 
Last edited:

Gyrob

Newbie
Joined
Oct 30, 2019
Messages
10
Location
Nebraska
We are searching for machine shops to make the parts now.
Or if you wish to make you own all of the design instructions are included in the PRA Ed kit.
I'm setting up a need separate from PRA LLC corporation called RotorLand in NV that will sell parts or complete finished projects,
This is for liability reasons. However, Rotorland buys the Ed kits from PRA and includes in the price so all will be buying PRA Ed kit one way or another.
This will assure that PRA Ed kits are self-sustaining and allow PRA to pay for many more projects for the good of our community.
There is an Ed kit in the works to convert an RAF adding a Lycombing O320 150HP certified aircraft engine you can buy with 1/2 time for about 5K.
Thanks for the update John,
I have a number of tasks keeping me busy to get this machine completed, so I would like to purchase the complete finished project when you have everything set up. Just let me know when things are ready and I will be in touch.
Regards,
 
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