Hi guys! I am abbabibble. the reason i have come here is to request help on some things. *ahem* i am currently in the design phase of a new ultralight, open cockpit helicopter dubbed "Simplicity V 1.0" i have a decent amount of knowledge on airfoils and the concept of how a helicopter works. All I need to figure out is where I can get rotor blades, or even better, construct/manufacture/build a set myself. This design requires one (1) set of two 5-7 foot long rotor blades (length of ONE blade, not whole wingspan) and TWO sets of 2-3 foot long blades. (Sorry if you all work in metric units... i can convert if needed...)I am seriously thinking about constructing the rotors the same way the wright bros. did their propellers... with wood and by hand.ALL help and comments would be GREATLY appreciated, and i am sorry if i do not follow board ettiquette.

Hi!Does this help?http://www.vortechinternational.com/http://www.avsim.com/hangar/fly/dfdg/banneraa.jpg

Without trying to sound like I am questioning your ability to construct this craft, playing "Wright Brothers" can be hazardous to your health. An ill constructed prop/rotorblade can cause a mirade of problems. I have a seperated AC and a pile of sticks and cloth to prove it. Finding a good grade wood to work with will be your first problem if you are going to make them from solid stock. Most wood avalible now days is kiln dryed and from young growth trees and is not the most stable in the long run. You are going to have to watch for warping, checking/cracking, and shrinkage. Laminating will help to minumize most of this but also can be easy to do wrong. Getting a even coat of proper adhesive and applying even pressure the full length of the blade is critical. Its takes more than a few clamps and elmers wood glue. Mounting is also a critical area to consider. With the varying forces put on a rotor and the properties of wood it would pay to sleeve any mounting holes put in the blade. And don't forget balance. Even your final finish can put a blade out of balance. If you are bent on constructing the blades yourself you may also consider doing a foam and fiberglass blade. Although that comes with it's own set of problems. Sometimes it's best to let those with expertise do some of your work for you. With all this said, I send my best wishes on your project, like to hear how things turn out. The concept sounds like a lot of fun. JohnnyV

Ok. Thanks. that really helps, and it would be very helpful for you to elaborate on the foam and fiberglass thing. I wanna consider all the options i can get. BTW: i am not playing wright bros... i have been designing this for about a year and a half now, and i have sought help from others who have built ultralight helicopters. this design is quite stable, i'm sure, and i am just ironing out all the littel flaws and saving my cash for the materials required.

>Ok. Thanks. that really helps, and it would be very helpful>for you to elaborate on the foam and fiberglass thing. The foam and fiberglass thing: This is the type of constrution used on a lot of surf boards. Basically you shape the part you are making in styrofoam. I have used both the type that line packages and the type over sheeting on houses. Shape and sand to just under the final size then you lay fiberglass over the part. There are many types of fiberglass matting as well as differing weights. Suppers ready so I'll be back later.

Some matting is woven and some as random chopped strands. For this application I would stick with woven matting of medium weight with multiple layers running in different directions. When laying fiberglass you want to make sure that the cloth is fully saturated and that all air bubbles are rolled out. The largest hurdle to over come is getting enough strength in the mounting area. For this you could laminate in metal plates or a combination of plates and sleeves where the bolts will pass through. I hope this helps a little. Any ?'s e-mail me..... [email protected]