SPORT USA, LLC., a new company, was formed out of the demand for a
better aluminum single and two-place rotor system. They have announced
their new rotorblade production line of “Sport Rotors”.
These fast selling rotorblades are the result of over 3 years of research
and testing. With the emergence of the new Sport Copter series, Jim
Vanek knew that his sophisticated gyroplanes would require the same
of its rotor system. He, along with outside consultants, went to work
and designed this new airfoil and hub bar assembly. As some of us
know, Jim formerly worked with his father, Chuck Vanek, innovating
the new “Vancraft” designs in the mid 1980’s. He
has flown in gyro’s since he was 9 years old, and at this young
age, could always tell when the gyro was ready to take off just by
the feel of the rotors and the sounds of the aircraft. His father
tested many different airfoils made of wood, vertical grain spruce,
fiberglass covered, in the 50’s and 60’s. Jim worked with
him, side-by-side, building “Vancraft Rotors” throughout
the 70’s and 80’s. The airfoil design of the blade was
the secret, …..High lift, Low drag.
Today, with the new high-strength aerospace adhesives, Jim was
able to work with products not formerly available. The all-new “Sport
Rotors”, made by “SPORT USA, LLC” , are now the
latest breakthrough in all aluminum rotorblades. The new adhesive
process, the first to be used on experimental gyroplane rotorblade
systems, has taken over 36 months to research and test. Jim has
brought in outside consultants who specifically work with these
new bonding techniques, which are currently used by “Boeing”
and in other helicopter rotor systems, fighter jets, missiles and
airliners. It is expensive and the processing is very critical in
that you must follow specific step-by-step, procedures. Approximately
52 steps in producing a single set of rotorblades! The blades are
chemically dipped in three separate tanks, and each phase of this
bonding process is timed to industry standards to insure accuracy.
The new bonding process uses a baked-on “Structural Adhesive
Primer” which provides a high degree of protection against
corrosive environments both inside and outside the adhesive bond-line.
This is one of the key elements in producing the “Sport Rotors”
as it is imperative to bake on the primer, prior to the bonding,
as done in all aerospace bonded metal structures, to keep the blade
surface, corrosion resistant and insure long life to your bond.
Consequently, this process requires three bake cycles. To date,
Sport Rotors are the only aluminum rotorblades available which use
this process.
The blades, along with test pieces, are baked in a state-of-the-art
oven, which is 20’ in length, 5’2” high and 4’
wide. These test pieces are peel and shear tested after each run.
When shear tested, one square inch, of each test piece, will shear
at 6 tons psi (per square inch). This is a guarantee that the adhesive
has adhered appropriately to the aluminum and releases through the
bond-line for “Perfect Adhesion”. The oven is made completely
of stainless steel, has a computerized digital temperature controller.
This controller is vital for exactness in the incremental rise in
temperature to the equally important incremental decrease in temperature,
which is necessary for the accuracy in this type of bonding. The
controller disallows the oven to “overheat” and regulates
the levels of heating which is required in order to properly seal
the blades. There are special external blower fans and an overhead
crane that lifts the lid. The oven is 240 volts at 10,000 watts
and able to ramp up to 300 degrees from a cold start within 60 minutes.
They are very excited about the smooth performance of the new design.
After many variations of redesigning the airfoil and many flight
tests later, this configuration has proved to be a winner. Flight
testing includes: best glide, slow vertical descent, slow flight,
high speed run, good rotor rpm recovery, high G turns (testing high
loading capabilities). In fact, during the “extreme”
testing phase the Sport Rotors were used for looping & Roll
maneuvers and rated “High” in overall performance! They
sport a high shine white epoxy urethane finish, which is enhanced
by the gold cadmium (or nickel finish) on the retention straps.
The Sport Rotors latest breakthrough in the design of their new
rotor systems is seen in the larger, 8” chord blades, specifically
at the hub bar. This is unlike any other hub bar design you have
ever seen. In adding a polyurethane mount, with a spherical bearing,
to the connection area of the blades, has allowed the blades to
pivot. Due to this configuration the rotorblades are able to find
their own lead, lag and coning angle. This simple design gives separate
pitch and track adjustability allowing them to fine tune their position.
The special mounting renders smoother movement during rotation and
this feature of self-aligning is helpful, especially for the pilot
who removes his blades from the hub bar between flights.
The four main factors that Sport Rotors set out to achieve, aside
from achieving a great airfoil and quality product, were: (1) Incredible
Performance, (2) Longer life of the Rotor System and Rotorhead,
(3) Pitch and Track Adjustability, (4) Ease & simplicity of
hook-up,…. And this is what they have achieved. This system
reduces bending stresses within the hub bar and rotorblades during
tensil load in flight (as in a helicopter), unlike other hub bars
which “cut out” inside the solid structure compromising
the integrity and weakening that area.
There is a definite performance difference in these larger chord
blades. The aspect ratio is wider, which allow slower descent and
a higher rate of climb. The 7” chord blades are recommended
for lighter aircraft, but the 8” chord blades are recommended
for high performance. This new rotor system was designed for longevity,
in that, any wear points (flexing on the bushing) can be replaced.
Thus, the blades are guaranteed for a lifetime of use.
They are currently selling these rotorblades to other manufacturers.
Mr. Joe Souza of “Joe Souza Gyroplanes”, or better known
by his design, “The Bandit” is a regular distributor
of the new “Sport Rotors”. He recommends these blades
to his customers and is extremely impressed with the remarkable
difference in performance. “These blades have really good
inertia, real smooth flying, right out of the box. They render quality
like no other aluminum blades we’ve used. My customers are
not only impressed with the great performance they give but they
look good, and add a professional touch to your machine.”
Customer Ron Spiess from Kerrville, TX…..”The Sport
Rotors are a work-of-art, they should be commended for the quality
and craftsmanship of these blades!”
Jim’s quote regarding these new blades: “These rotors
are the finishing touches for our Sport Copters. Their quality,
style and performance compliment each other, making the Sport Copter
complete.” Sport Rotors have been sold, as standard equipment
for the “Sport Copter” customers, and now the demand
is growing since these blades started to enter the market.
They balance, track and fly every set of Sport Rotors before shipping.
The tracking tabs (one red, one white) are left on the blade ends
so you can track your blades at home!
UPDATE -- JAN.2003
We have added a new step to the Sport Rotors Rotor System manufacturing
process. The blades, in the past, were buffed and polished leaving
a high mirror shine finish. The problem with this type of surface
is that the blades are susceptible to corrosion over a period of
time. We have received feedback from our present customers who are
requesting a more "low maintenance" surface which will
not require a lot of upkeep. So we now have added a new "painted
on sealant" which will not only make the blades look superior
but will be less maintenance on its owner in the long run (and will
prevent corrosion). This is the same finish used on helicopters
and jets. No other aluminum blades are using this level of quality.
First, we apply the Corrosion Proofing, then we apply the Primer.
The blades are then painted with a White Urethane Paint. This sealant
system, you will find, will insure the longevity of quality on the
surface of your new Sport Rotor Rotor System.
We currently have distributors in Jordan, Japan, Spain, Russia
and Czech Republic
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