Hope everyone got along OK through another winter. I'm sure glad the warm weather is on it's way.
Last fall my interest was peaked when I did some research into carbon fiber manufacturing. I found out a lot of intersting things. It's cheap, light weight, stiff and fairly easy to work with. I also looked into rotor blades. The largest rotor blades being manufactured today are almost 500' in diameter. That's huge! Their being mounted on giant masts as wind turbines. They pivot into the wind and a radar system reads the local wind speed far enough out that the blades can change pitch in advance of a wind gust. The plan, for coastal countries, is to mount these units on off shore bouyes like giant fishing bobbers. This way they will be ble to capture the sea breases.
I developed a plan to make a set of "one off" rotor blades for a Hiller. They will be a hand laid, vacuum bagged, clam shell design. They will be the exact dimension and weight of a standard blade and of course be made of carbon fiber.
The plan revolves around the techniques employed. I developed a low cost machining jig and mold set. I will be testing it as the weather improves as my work space is unheated. The test pieces will be in hand laid fiberglass and be limited to sections under 2' in length. I don't really expect to ever get an order for a set of blades but I am quite capable of making them. Just so you understant, this is a pipe dream.
My backround. I grew up in the mold making business. My Father and Granfather were in the statuary and casting trades and owned a business that made custom molds for lamp and trophy manufactures. As a youth I repaired fiberglass boats and later did some automotive bodywork. I am a finish carpenter. I worked with Corean. I build oak staircases from scratch. I took classes on composite structure fabrication and repair at Vaughn College. I hold one US Patent and have two others in process.
If I were ever to make a set of blades they could only be flown on an experimental aircraft. I would have to make three blades. One for destructive testing. Before I could build anything I would need a run out blade to pattern off of. Could even make a Bell 47 blade as the are both symetrical in cross sectoin.
Also, I found a design company that has the staff that can design a radical blade and create the molds for it on their giant CNC machine. But here were talking major dollars.
So I put this out there. I will test my ideas. If someone wants to go the the next level, I am ready, willing and able. All I need is a solid commitment from a person going in with both eyes open.
I am expecting another good year with my propeller balancing / rotor tracking business. Search Barnstormers, key word 'dynamic', to find my ad. Hope everyone else expecting a good year too.
Hudson Valley Aviation