(Backward Engine Girocopter) : Electric Pusher Gyrocopter
(Backward Engine Girocopter) : Electric Pusher Gyrocopter
(Backward Engine Girocopter) : Electric Pusher Gyrocopter
Now that you have been warned, lets proceed to build this model.
Building
You can build the sub assemblies in any order. Final assembly will of course require the sub-assemblies.
The assumption is that you are an experienced modeler. Where some portion of the design is non-critical,
this will be pointed out such that builders preference may be satisfied. Glues will not be specified unless
they are critical to a step, and this will be pointed out.
Chassis.
Glue the two laser cut plywood chassis parts together with thick CA. Do this over plastic wrap or wax
paper. Sand the joint smooth. Roughen the top of the tail boom with sandpaper and glue the chassis to the
© Copyright 2005, Charles M. Nowell, Jr. 2 All Commercial Rights Reserved.
boom. Make sure to leave ¼” of the tube sticking out the front of the chassis. Also make sure that the
chassis is perpindicular to the boom. Apply a small fillet of glue to the chassis boom junction.
Glue up the main landing gear pieces, the two pieces with extra slots
are the inside pieces. Glue this well with slow curing glue, make sure
to get enough glue on the lower section where the carbon fiber will
go. When done use a 5/32” drill in your hand and slowly round out
the whole for the carbon fiber landing gear legs.
Take a hobby knife and slowly elongate and enlarge the center hole
so the landing gear block will fit on the tail boom tube and lie flat
against the front of the chassis. The angle is important to making
sure that the wheels end in the right place.
When satisfied with the fit, tack glue the landing gear piece to the
chassis with thin CA. Double check the alignment to make sure that
the chassis is vertical and the landing gear mount is square with the
chassis when viewed
from the top. Then
apply thick CA to the
joints and allow to cure.
Cut the trailing of the fin and the leading edge of the rudder at an angle as shown in the photo. The angles
should create a “V” on the right side of the fin/rudder. Round of the other edges of the fin and rudder. Lay
the fin and rudder flat with the “V” down and apply clear tape to the hinge line. Fold the rudder all the
way back and apply tape in the “V”. It helps to leave a small gap so the two pieces of tape can stick
together at the hinge line. 3M Brand “Blenderm” (tm) works well for the hinge.
75.0°
The head has a strengthening modification that can be done during construction or later after a few
“mishaps”. Its probably best to do during construction. Take the head center hub ( the part with the
bearings) and attach the main head plate by snapping it onto the bearings. Take an Xacto and cut a small
(1/16”) notch out of the head blade diagonal bracing directly above the bearings. Line this up with the
little grove on the outside of the bearing holders. Now take the kevlar thread and make 3 or 4 turns around
the head and the bearings, effectively lashing the bearings into the head. Tie off securely on the top of the
head ( an extra pair of hands will help here) and then apply a couple tiny drops of CA to the thread on the
top of the head only. Be careful not to flood the CA or get any in the bearings. If you happen to get CA in
the bearings (not like I’ve ever done this or
anything) you can soak them in acetone or
debonder until they free up.
Glue the 1/32” ply anti-rotation link base to the side of the gearbox opposite the big ring. Sand the surface
of the gearbox first. Glue the two carbon fiber rods to the ply so that they are on either side of the little
post on the swashplate. The swashplate needs to be able to spin and slide in the slot you make. The top
position of the rods is set by tilting the flybar down as far as possible then making the rods just clear the
bottom of the flybar. Put large CA fillets on the carbon rods so they stay on the ply.
Drill a clearance hole for a #2 screw on one side of the gearbox. Slip the gearbox on the main mast with
the ring forward. The gearbox
should fit very snugly with no
wobble. If there is some wobble,
Blades
Blade construction is important to the overall flying characteristics of the model. Proceed slowly and
carefully.
Roll the 1/16” solder on a smooth surface under a flat board until it is smooth and straight. Cut in half.
Line the two pieces up and make sure they are the same length. Drop the solder in the blade slots, making
sure that the solder does not stick up out of the slot. Place one blade on top of the other with the tips
aligned. Now make sure that the solder is in the same place along the span of the blade. Ignore the
Now sand the blades overall with 220 grit sandpaper. Use a block not your fingers. Wick thin CA down
the last 1/8” the whole length of trailing edge. Sand this smooth when cured.
Spray a heavy (but not runny) coat of instant drying lacquer (Ace Hardware is where I get mine) on both
blades. Let dry, sand with 320 grit sandpaper, clean the blades with a tack rag and repeat at least one more
time. Final sand with 320 or 400 to a smooth surface then apply one LIGHT dusting coat of lacquer.
Don’t sand this coat out, leave it shiny so the covering will stick to it. Here you can use other hobby
materials like dope or other sealer material. The goal is to seal the grain some so the blade covering will
stick to the blades, especially near the trailing edge and leave a smooth surface for the blade covering to
stick to. The goal is to get a sealed surface but not necessarily fill all the grain like you are going to paint.
You just want the wood surface to be smooth and shiny.
You need a scale that reads to 0.1 gram for this step. Weigh each blade. Apply lacquer or whatever you
used to the lighter blade and let dry completely. Continue this process until both blades weigh the same to
0.1 gram. This is where the instant dry lacquer is helpful. If you apply too much lacquer to the lighter
blade, making it the heavier blade, its okay to sand the excess off with 400 grit paper. If you do use
sandpaper, make certain that you use a tack rag or Prep-Sol on the blades to get the dust off before
covering.
Peel the backing off the blade covering and put it sticky side up on a flat surface like a kitchen countertop.
Hold a blade with the root to your left, leading edge up and the bottom surface facing yourself. Place the
trailing edge down on the covering with the tip aligned with the right hand edge of the covering with the
blade 3/16” of an inch in from the edge of the covering closest to you. Lay the blade down on the table
Radio
Radio installation is usually where each builder will customize. The general instructions will be given
here. Customize if you like but please read this section to determine the critical bits.
Rudder
The rudder is setup for pull-pull control using the supplied dacron ½ flying line. Use thick CA and glue
the rudder servo upside down to the tailboom, right at the tailboom to main mast junction. Make sure the
rudder horn is the 4 sided type (star) (or circular type) and that the horn will clear the bottom of the tail
boom. If the servo arm has two long and two short arms, arrange it so the long arms are perpindicular to
the tail boom direction. Tie one end of the line to the rudder horn and CA. Pull the line forward to the
appropriate side of the servo. Go through the outer hole in the servo arm, come back around and go back
through the same hole. Leave a few inches sticking out and cut the line. Repeat for the other side. Take
the #1 screw and 2, #1 washers and screw this into one of the servo arms that does not have the dacron
line attach. Don’t tighten yet. Now center the servo and the rudder and pull both dacron lines tight. Take
the loose ends and wind them a turn or two between the two washers. Now making sure that the lines are
taut and both servo and rudder are centered, snug up the #1 screw. This screw can be used to adjust the
centering of the trims if necessary. Now adjust the tail wheel linkage (twist the wire) so that the tail wheel
is aligned with the rudder.
Connect the roll servo to the aileron channel of your receiver, the pitch
servo to the elevator and rudder to rudder. Hook up whatever speed
control and battery you intend to use to the throttle channel. Make sure
the rudder moves right with right rudder stick. Up elevator should tilt
the front of the swashplate UP. Down elevator should tilt the front of
the swashplate DOWN. Right aileron should tilt the right side of the
swashplate DOWN, left aileron should tilt the right side of the
swashplate UP (viewed from the rear).
Adjust the trims and servo horns as necessary to get the rudder
centered and the swashplate square to the rotor shaft. The swashplate
should tilt about 30 degrees up or down in all directions at full throw.
The rudder needs about 30 degrees of throw. This is just the initial
setup, see initial flights section for the final settings. This finishes the
radio initial installation excepting the motor and speed control. Attach
the receiver to a convenient place with double sided tape or velcro.
Attach the blades to the head with the #10 washer, the
head stiffener and the 3mm bolts and plastic stop nuts.
Place two washers on the bottom of the head, and one
on top. Slip the metal blade straps around the
washers/head. Put the head stiffener in place on top of
the metal strap, then screw the whole thing together
with the 3mm bolt and lock nut. Don’t tighten all the
way until both blades are on. Now tighten the blade
bolts until the blades are very snug. Very snug means
that you can move the blades by hand but if you give
the head a quick flip to rotate it the blades won’t move.
Using a pair of slip joint pliers to hold the blade
attachment bolt and a pair of needlenose on the metal
blade straps, adjust the blade pitch. Adjust by looking at
the end of the blade and comparing to the FLYBAR,
not the main shaft or swashplate. Adjust so that the
trailing edge is higher than the leading edge by the
thickness of the leading edge. Basically make the
middle third of the top of the airfoil parallel with the
flybar. This is just the starting point. The final position
will be determined by flight testing. Make sure you
take the pliers with you to the field to adjust the pitch.
Flight Test
Here’s the magic moment. Ready for flight. It is best to wait for perfect conditions to do the initial
trimming, later you can fly in rough conditions. The ideal circumstance is a smooth paved surface and a 3
mph wind right down the runway. Early in the morning at big parking lot is ideal. The first steps are just
to get the trim settings correct before actually flying around.
Start with about level aileron trim. The swashplate will be level looking from the rear. Put in about 10
degrees of down elevator. The swashplate will be tilted down about 10 degrees from the main shaft. Line
the blades up straight and then give the head a little spin. If you have a breeze the blades should keep
turning. Either way put in a little blast of throttle then back off to around ¼ throttle. The blades should
begin to spin up. Slowly add throttle until the blades really start spinning, you probably won’t need more
than about half throttle if you have one of the recommended power plants. Don’t take off yet. Throttle
back and taxi back. If the blades spun up right away and came up to speed you’re ready for a hop. If the
blades never sped up and things got all wobbly, reduce the pitch of both blades. Repeat until you get a
good rotor speedup in about 50-75 feet. The rotor should be spinning very quickly and be very stable. If
the rotor wobbles around and won’t speed up and you have the proper pitch, the blades may be loose or
not aligned or both. Tighten the main bolts (the ones with the plastic stop nuts) until the blades are
© Copyright 2005, Charles M. Nowell, Jr. 16 All Commercial Rights Reserved.
difficult to move by hand. Now straighten the blades so they are directly in line with one another. Sight
down one blade, the head stiffener and the other blade so that it makes a straight line. Give the head a
hard spin by hand and let it wind down. The blades need to be tight enough to not move out of place when
you make the hand spin. If you got the blades straight and tight enough a smart spin by hand will result in
a nice smooth wobble free rotation. If spinning the rotor makes one of the blades move, the bolts aren’t
tight enough. Once you have a nice smooth spin by hand you should immediately give some power on the
motor and start a fast taxi, at that point the rotor should start accelerating and rapidly come up to flight
RPM. If you give the hand spin and taxi and the rotor slowly slows down as you taxi you have the blades
set with too much positive pitch. Lower the pitch of both blade and try again until with a good hand spin
and a quick taxi, the rotor will accelerate up to flight RPM. Another test of correct settings it to hold the
model up nose high about 60 degrees into the wind and spin the rotor head. If you have a wind or can
walk or jog forward the rotor will rapidly come up to flight RPM. You will notice that once flight RPM is
reached the lift of the rotor will greatly exceed the weight of the model. Once the model is trimmed you
can drop the nose to level, add power and fly away from a hand launch. However this is NOT suggested
until the inital trimming is done from a runway. It is however a good way to determine if the rotor is set
correctly for takeoff.
When you have a good reliable startup make a single hop. Repeat the spin, burst of power, power back
off, then feed power in cycle. Get the rotor up to speed. Now add power slowly and smoothly to about ¾
throttle. DO NOT PULL UP ELEVATOR. It will simply pitch up, roll over and break something. You
must let it fly off with power all by itself. If you try to force it off with elevator it will simply crash.
Takeoff occurs when the rotor is fully up to speed and you have enough forward velocity. At that point
the model will simply fly off on it’s on.
As soon as the model breaks ground throttle back to ½ or whatever it takes to fly level at a few feet of
altitude. If you hold ¾ or full power on it will climb out quickly. Let the model break ground and watch
for roll trim. Be ready to put in aileron correction. Also be ready to gently power back and let the gyro
settle back in to a landing. Do not chop throttle! At the takeoff attitude chopping throttle will result
in the model coming to a dead stop and dropping from whatever height you are currently at. The
gyrocopter does not stall but this does not mean that it cannot have a very high descent rate! Reduce
throttle firmly but smoothly to fly level. Reduce the power until you have a nice descent back to the
ground use a little up elevator to come to a nice landing. It will probably take ¼ to 3/8 throttle to maintain
a gentle descent. Adjust the trims, roll and rudder should be obvious. If it takes full throttle and very high
speed to take off, there is too much down trim. If the model takes off too early and rolls over you have too
much up trim. You can hold some down elevator for takeoff or re-trim to correct this. Sometimes I have
to hold some down elevator while the rotor is spinning up, especially in windy conditions, then after the
rotor is spinning rapidly you can release the down elevator and continue to takeoff normally.
After a few passes you should have a model that will spin up, takeoff smoothly, fly straight and level and
land when power is backed out smoothly. If you have enough room I suggest that you make as many
straight “hops” as you can for longer and longer distances. Get the feel of how the climb or descent is
controlled completely with power, not elevator. Make some gentle “S” turns to get used to how it turns
and how to coordinate the rudder. Spend as much time as necessary to get used to using the left stick on
the transmitter. If you fly helicopters or 3D airplanes (meaning that you know how to hover an airplane)
this should be instinctive and you will know what to do almost right away. If you don’t have helicopter or
3D airplane experience it may take some time to get your left thumb limbered up. The gyrocopter flies
with the left stick. You make lots of throttle changes, you coordinate heavily with the rudder and you use
the right stick to keep the bank angle correct and pull up in the turns. Down elevator is used very little.
Use down elevator to stop a zoom, but only gently. Too much down will stop the rotor, resulting in a
Once you have gotten the feel of the model by making straight hops, you are ready to make a circuit
around the field.
Make sure you have enough room to make a left hand pattern. The model tends to pull out of a left hand
turn and tighten up a right hand turn. It’s not major but its easier to get a few left handed turns in first.
Takeoff as before. Add enough power to climb out smartly. Now make a left hand pattern. It really helps
to coordinate rudder with aileron. Trouble happens when the tail is allowed to slide inside the turn, so
keep it nice and coordinated. When you make the turn back to final, reduce power until you get a sink rate
that will put you anywhere on the field. The rollout is zero so don’t worry about runway in front of you,
just make the field somewhere. You will probably need something like ¼ to 3/8 throttle to maintain a
reasonable descent. As you near the ground feed power in so that you basically fly level with the ground.
A little up elevator and killing the throttle will result in a little plop landing with little rollout.
Congratulations, you just got checked out in a gyrocopter!
Once you can make a circuit have a helper set the track. Remember those little squares on the blades? We
put them to use now. Make a left hand pattern but don’t land, just make one pass down the field and have
your helper look at the tips, then go around once more and land. One of the blades will likely be running
higher than the other and giving you a shake. The tape is misaligned so you can see if the “in” blade or the
“out” blade is running high. The adjustment procedure is to lower the pitch setting of the high blade if you
think the rotor speed is too low and/or startup is on the edge of unreliable. Raise the pitch setting of the
low blade if the rotor speed seems high or the startup is very quick and the model flies fast. If you
balanced the blades well the model will get very smooth when the blades are tracking properly.
Now you are all trimmed up. Practice left and right hand turns and start enjoying the unusual flight
characteristics of the gyrocopter.
One final note. It is possible to land with the motor off. Go up high, cut the motor and put in some down
elevator to maintain some forward speed. When you get close to the ground pull up to flare and it should
just plop right in for a no rollout landing. If you are quick about it you can quickly add power and takeoff
while the rotor speed is still up.
75.0°
0.50 in.
Plastic tubing
(2 Each)
1/16 Ply
Tail Wheel
Assembly,
Rear View
1/16" Wheel Collars
0 1 2 3 4 5 6 Copyright
Inch Charles M. Nowell, Jr.
0 2 4 6 8 10 12 2004, 2005
cm All commercial Rights Reserved
6
5
12
6 mm Depron
4
10
Fin
1/32 Ply Control Horn
6 mm Depron
8
3
Rudder
6
2
Rudder horn l
o we
1" d
Fin outline ¼x
oom
tail b
into
Fin Glue Embed in foam safe
ron
or De p CA, then apply tape
ent f
0
0
Inch
force
lsa Rein around bottom of
" Ba rudder.
1/32
1.50 in.
B oom
Tail
#2 screws/washers
Sand Upper Surface
Flat in this shape
0 5/8"
Leading Edge Leading Edge Leading Edge Leading Edge Leading Edge
Spruce or Basswood
Balsa
1/32” Ply
Trim off
Blade
1 1/4"
Reinforcements
0 3/4"
Balsa
Spruce or Basswood
½”
1/8"
Leading Edge Leading Edge Leading Edge Leading Edge
1/16" Groove
0 1/4"
3"
16"
Copyright
Charles M. Nowell, Jr.
2004, 2005
All commercial Rights Reserved
3/8" = 1" Notes:
Blades : 1-½” Aerobalsa
RotorBlade™ Airfoils, cut to
6
1
2
4
Copyright
1
0
Himaxx
2812-
4
850
1
SF
Bamboo
APC 10x4.7
1/8" Lite Ply Skewer
0
cm
Inc
h
3S1P 105
0-1320
LiPoly
¼x¼
Spruce ¼” ID x 15-1/4"
6"
Bind With
Thread
70°
Bamboo
Skewer
1.5"
Copyright
Charles M. Nowell, Jr.
2004, 2005
All commercial Rights Reserved
1) Hang model
from flybar
2) Move battery
until model hangs
as shown
-1 3 2 0
1050
3S1P iPoly
L