This journey began on April 22nd 2006 when my then fiancé and I attended the Sun-n-Fun air show in Lakeland Florida and took notice of the Rotorway Exec162F experimental helicopter. This helicopter can be home built in as little as 450 hours. I then learned of builders installing gas turbine engines in this same helicopter that proved to be more reliable and less of a workload on the pilot. So it started, I purchased 2 Solar T-62T-32 gas turbine engines from a government auction on April 26th and have not looked back since. I purchased Group 1 of the Rotorway 162F new from another builder who changed their mind after they took delivery of the crates. I flew to Ohio picked up the Helicopter in a Ryder moving truck and proceeded home (via Homer's of course) to start my build. I'm building the Jet Exec version for many reasons.
Updates:
December 2006- I'm designing my own "low mount" turbine installation rather than go with the KISS version. I want a lower CG and a more aesthetically pleasing look for the conversion. The 162F is a beautiful ship and I want to keep the clean, sleek lines it already has.
March 2007- Construction of the complete airframe is complete and now I can start on the modifications needed for the low mount turbine and the shaft driven tail rotor assembly. I was able to source the KISS tail rotor gear box and had the manufacturer custom make me a new version complete with a one piece shaft that'll accept the OEM Rotorway tail rotors.
July 2007- Off to Homer's for the annual meet. Build is going slow as that "work" thing keeps getting in the way.
October 2007- Starting on the design stage of the low mount turbine. Working out fit and location issues for all the major components. I was able to source a lighter, non-quick change race car rear end for the main rotor transmission. I'll be using a centrifugal clutch with a poly chain belt reduction so there is no need for the Rotax C box for reduction speed of the turbine output.
January 2008- Progress is a little slow as work keeps getting in the way and I took a much needed vacation with my wife to Australia. I'm finalizing the design and layout of all major components. I'm getting a lot of help from fellow Rotorway owner and builder Peter MacDonald in Australia as he and I are working toward the same goal. It's just a little hard as he is half way around the world. We had a great visit in November of 2007 and worked out more details. Awaiting delivery of the main rotor gearbox.
April 2008- It's off to Sun-n-Fun in Lakeland for some much needed inspiration to keep moving forward with my project. I'll meet up with MANY other owners and builders from around the country.
July 2008- All the details have been worked out for the design and I have started drawing up the parts using AutoCAD so I can have them laser cut from aluminum or steel. This ensures they are a perfect fit. Peter came up with a nice design for the tail rotor gearbox mounting plates. This will allow us to do away with many of the OEM Rotorway parts inside the tail boom. Thanks Peter.
September 2008- Part drawings complete for the tail rotor gearbox mounting plates. Time to order material and have them cut from aluminum for the first trial fit. Once back from the cutter it'll be time for assembly and testing of the linkage.
October 2008- First run or parts for the new tail rotor setup are a little heavier than I want so I'll add some holes in the parts to help lighten them up without taking away to much or the structural integrity of the parts.
December 2008- Finally, the new parts are perfect and the weight is considerably less than the first run. They look great and everything is falling into place with the tail rotor gearbox design. My tail rotor drive is very similar to the KISS design in that it uses a 3 piece shaft from the jack shaft to the tail rotor gearbox. These sections are separated by flex couplings at each bulkhead. Also a flange bearing supports the shaft at each bulkhead. The flange bearings are isolated from the tail boom vibration with rubber dampeners. Thanks again to Peter for his help and ideas.
February 2009- Tail rotor setup nearly complete. All parts fit well and I have more than enough travel on the slider assembly. Looks like I'll have a bit more t/r authority than stock. Final assembly of the t/r section is next and installing the t/r shaft.
April 2009- Not a lot of progress to post. Sun-n-Fun is this month as well as Bob's pre Sun-n-Fun gathering in Lake City.
July 2009- Well it's off to Homer's again. Won't get much done this month either. Tail boom is now complete and everything works as planned.
September 2009- Made it back from Homer's and it was a great trip. The factory was there showing off some new products and it was good to see everyone again. Weather was not so great but being around great people and helicopters in the rain sure beats a good day at work. Thanks Homer.
December 2009- I have torn down the entire tail boom for paint and powder coating. Next it's time to remove the actual tail boom for painting. I'm hoping to get the tail boom 100% completed in the next few months. I've been working on the new fuel delivery system with new filters and pumps. Also trying to sort out some final design parameters for the lower belt drive.
February 2010- I've started on the engine mount to attach the solar turbine in the airframe in the same location as the piston engine was mounted. I'm using the same bushings in the airframe that the piston engine mounted to and i added to attachment points up higher for added support.
April 2010- The engine is in the airframe with the help of a few new friends. Now it's off to Sun-n-Fun.
June 2010- The parts for the new tail rotor drive system have come back from the powder coater and it's time for final assembly of the tail rotor gearbox and blades.
July 2010- My wife and I just bought a new house so the helicopter is on hold for a while.
