January - present, 2008

2008-05-05

• Began testing the rotor for our new 4-Place PAV prototype in the test pit. As per our usual conservative approach, we will perform many test runs on the rotor, incrementally increasing the rpm. Thus far, we have reached 250 rpm, with a planned maximum of 450 rpm (.95 Mach tip speed). During flight testing, we will limit the rotor to a maximum of 400 rpm, which will only occur for max performance jump takeoffs. The automatic mechanical collective and jump takeoff rotor pitch control appears to be working well. We are making a slight adjustment to the spring rate, and will continue testing this week.
• We are working with Greg Richter (founder & CEO of Blue Mountain Avionics) to develop our avionics, data collection system, video, auto pilot, electronics, and controls for the tilting mast, rotor rpm, wing angle of attack, and for optimizing propeller efficiency. He visited our facility this month to see the aircraft and kick off the project.
• Received the actual Lycoming IO-540 that will be used in the aircraft (as opposed to the non-functioning version we previously used for layout purposes), and have begun making the engine mount.
• Continued work on the horizontal stabilizer. Per advice from Greg Richter, we mounted antennas inside the horizontal stabilizer, and then bonded the skins together. Performed the prefinish on the outboard vertical stabilizers that will be bonded to the horizontal stabilizer.
• Bonded carbon reinforcement to the strongback around the bracket that will hold the rotor mast.
• Installed a conduit down the length of the tail boom for running wire.
• Installed the wing root fairing & began prefinishing the underside of the fuselage.
  
  

  Rotor in Test Pit Lycoming IO-540 Engine Horizontal Stab & Tail Boom Outboard Vertical Stabilizer

2008-04-07

• Update 2008-04-08 Jay Carter will be giving a presentation at this year's Sun 'n Fun Fly-In, titled "Carter's New Personal Air Vehicle And The Future." His forum will be at 12 noon on Friday, Aprill 11th, in Tent 11 (not 7, as previously stated).
• Polished the windshield & installed it in the canopy of our 4-Place PAV prototype.
• Test fitted the Lycoming IO-540 in the engine compartment. We made a slight modification to the firewall to provide more clearance. We are currently working with Lycoming on an exhaust to fit in the engine compartment.
• Installed the 4-bladed MT propeller onto the drive shaft, test fitted it on the aircraft, and trimmed the fuselage accordingly. To allow us to fly sooner, we will initially use this commercially available propeller. Once flight testing has begun, we will begin development of a Carter scimitar propeller.
• Continued work on the horizontal stabilizer. We have completed all the composite parts, and pre-bonded the internal ribs and shear webs to the skins. We are waiting for experts from Blue Mountain Avionics to visit this week, where among other things they will help locate the antennas inside the horizontal stabilizer before we bond the skins together.
• Completed the canopy latching mechanism.
• Tested the cyclic link fittings & made changes to the design per the test.
• Modified the instrument panel to provide more leg clearance.
• Completed installing all electrical components in the rotor head, including sensors and the solenoid to engage the automatic mechanical collective. Finished work on the electronic data collection system in preparation for testing the rotor on the test stand.
  
  

  Jay Carter in the PAV Engine Test Fit in PAV PAV with Canopy Open PAV with 4 People PAV with Prop, Engine Cowling & Panels Horizontal Stabilizer Ribs & Shear Webs Calibrating Electronics at the the Rotor Calibrating Electronics at the Collection System

2008-03-03

• We received a non-functioning version of the engine that will go in the first 4-Place PAV prototype, to use for fitting purposes. It is a Lycoming IO-540. We are currently working with Lycoming to make a few modifications to the exhaust so that the engine will better fit in our engine compartment.
• Received our windshield from the manufacturer. Unfortunately, the windshield didn't follow the proper contour, and wouldn't fit properly into the canopy. We had to heat and vacuum form the acrylic ourselves to get the correct shape. We are currently polishing the windshield, and will then install it in the canopy.
• Received a 4-bladed prop from MT propeller. To save development time for the first prototype, we will initially use this commercially available propeller. Once we have completed all the work necessary to begin flight testing the aircraft, we will begin development of a Carter scimitar propeller. Having both propellers will provide a very good apples to apples comparison of the performance of a Carter prop to a more conventional design.
• Began work on the horizontal stabilizer. We laid up the skins, made all the tooling for the internal ribs and shear webs, and have begun laying up those internal parts.
• Built and installed the hydraulic master cylinder assembly that will pressurize the prerotator and rotor brake.
• Began work on the canopy latch.
• Continued installing the electrical components in the rotor head, including sensors and the solenoid to engage the automatic mechanical collective. We also began work on the electronic data collection system to input the data from those sensors in preparation for testing on the test stand.
  
  

  Canopy Latch Paritally Completed Horizontal Stabilizer Skins MT Prop & Spinner, Still in Packaging Lycoming IO-540 (non-functional, for fitting, only)

2008-02-04

• Performed a static test on the composite tilting mast for our 4-Place prototype. This test was performed not just on the mast itself, but also the air over hydraulic cylinder that will control it, and the mounting hardware. A steel pivot fitting in the mast failed at a load greater than what is possible in flight, but less than our design proof load. Subsequent analysis revealed an unanticipated bending moment on the fitting, due to the pivot pin not being sufficiently rigid. The pivot pin has been redesigned. While we are rebuilding the mast, we are beefing up the structure to give it an even greater safety factor.
• Changed the canopy from a sliding mechanism to a tilting mechanism, which is simpler and more reliable.
• Completed installing cables & pulleys for the rudder and horizontal stabilator control.
• Completed and installed the upper linkages for the cyclic control.
• Created a pull test fixture and began making test specimens to verify the bond strength of a new resin system.
• Began installing the electrical components in the rotor head, including sensors and the solenoid to engage the automatic mechanical collective.
  
  

  Tilting Mast Static Test PAV with Closed Canopy PAV with Open Canopy

2008-01-07

• Performed an 18,000 lb static test on the rotor head & made a few changes to the design based on that test.
• Began installing cables & pulleys for the rudder and horizontal stabilator control.
• Completed the mold for the instrument panel & laid up the part. Test fit panel in the aircraft.
• Built the plug & mold for the outboard vertical stabilizers, then laid up & bonded the actual parts.
• We've decided to change the canopy from a sliding mechanism to a tilting mechanism. This will be simpler and more reliable. We're nearly completed machining the parts for the hinge, and will begin modifying the canopy and fuselage shortly.
• Built a false floor to go above the wing & below the rear seat. Modified the installation of the rear seat for increased headroom & leg room.
  
  

  Rotor Head Static Test Instrument Panel Outboard Vertical Stabilizer