ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-28
RAF 2000 GYROPLANE
NO. 28: CRANK TRIGGER IGNITION, (CTI), EJ22 SUBARU ENGINE
The following situations can cause damage to the CTI system upon installation and use:
1. It has come to our attention that the CTI system can be damaged if any of the plug wires are un-hooked
and the engine is cranked for any length of time. For example: doing a compression test.
To avoid this damage, unplug the coil pack from the CTI box at the coil before doing a compression test.
2. The electronic components inside the CTI box could be damaged from improper mounting of the CTI box.
Improper mounting can cause the boards that are inside the CTI box to twist and cause separation or
damage to the components mounted to the inside of the CTI box.
Before mounting the CTI box use a straight edge across the 2 angles and the mast to ensure that the area
that you are about to mount the CTI box to is flat. Shimming may be required to ensure that the CTI box is
mounted to a flat surface.
3. WARNING SIGN. If on engine start up, the engine is running very rough, or on 2 cylinders you have a
problem. DO NOT fly the aircraft. Contact the factory for service.
*NOTE: AIRCRAFT PRODUCT NOTICE NO. 28 CRANK TRIGGER IGNITION, (CTI) outlines installation
and operating procedures.
Issue Date: 15 February 1999 Revision Date: 17 Aug 2011 Revision No: 002
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ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-29
RAF 2000 GYROPLANE
NO. 29: •EJ22 SUBARU ENGINE CAM BELT DRIVE SYSTEM 25 hour inspection
•800-022-S12 OUTER PRE-ROTATOR CABLE NS98 (SHINY BLACK) - RECALLED
•REVISED 25, 50, 100, 200, 500 HOUR INSPECTION/MAINTENANCE SHEETS - October
1999
•EJ22 SUBARU ENGINE CAM BELT DRIVE SYSTEM 25 hour inspection: A RAF 2000 owner has recently had a
failure of one of the CAM BELT IDLERS which in turn caused an engine out situation. This owner had
approximately 150 hours on the EJ22 Subaru Engine and noticed a strange noise coming from his engine
approximately 6 hours before the idler seized. NOTE: If you hear a strange noise you must determine the cause
before flying.
The following is an assessment by RAF: One of the new bearings which was installed in the pulley located to the
immediate right of the crankshaft sprocket failed causing the pulley to seize. This in turn caused the crankshaft to
strip the gear teeth off of the timing belt. RAF believes that shrapnel from this seizure caused damage to the cam
tensioner pulley.
TIMING BELT and IDLERS 25 hour inspection: To inspect, remove the outside belt covers and inspect the
condition of the timing belt and idlers for excessive belt dust or large amounts of grease on the covers. If this
condition arises the timing belt should be removed as per the Subaru instructions and check for roughness of all
idlers including the water pump. Check all the bolts for the proper torque as per the Subaru Manual. See the
following drawing REF:C/PRONOT.RAF-29 taken from the Subaru Manual.
•800-022-S12 OUTER PRE-ROTATOR CABLE NS98 - RECALLED: This SHINY BLACK outer cable with the
screw in ferrules was shipped out with kits and parts orders after July 1998 to April 1999. RAF has contacted
owners affected and most shiny black outer cables have now been replaced with
800-022-S13 OUTER CABLE ELT8/99. However, you should be aware that the shiny black outer cable is
RECALLED.
For the owners affected, the 800-022-S13 OUTER CABLE ELT8/99 will be charged to your account until 800-022-
S12 OUTER CABLE NS98 (shiny black) is returned to RAF then RAF will reverse the charge.
The 800-022-S13 OUTER CABLE ELT8/99 should be better in cold temperatures. See the following reminder
regarding PRODUCT NOTICE NO. 26 regarding cold temperatures and proceed with caution.
PRODUCT NOTICE NO. 26: •PRE-ROTATOR OUTER CABLE SHEATH - COLD -20C, or -10F WEATHER
Issue Date: 13 October 1999 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-29
RAF 2000 GYROPLANE
WARNING: In cold weather operation, it has been found that the PRE-ROTATOR OUTER CABLE SHEATH will
continue to harden as the temperature decreases. RAF has determined that there will be a restriction of the aft
movement of the controls when the temperature reaches -20 Celsius or -10 Fahrenheit. This WARNING still
applies to the original OUTER CABLE with crimped on ferrules (prior to July 1998) as well as the Shiny Black outer
cable shipped to April 1999 and now recalled.
•REVISED 25, 50, 100, 200, 500 HOUR INSPECTION/MAINTENANCE SHEETS - October 1999: Use these
inspection/maintenance sheets to replace the sheets from the RAF 2000 Flight Manual Operating Limitations
revised September 1996. Make additional copies for on-going maintenance records.
*NOTE: AIRCRAFT PRODUCT NOTICE NO. 29 •EJ22 SUBARU ENGINE CAM BELT DRIVE SYSTEM
25 hour inspection, •800-022-S12 OUTER PRE-ROTATOR CABLE NS98 (SHINY BLACK) -
RECALLED. •REVISED 25, 50, 100, 200, 500 HOUR INSPECTION/MAINTENANCE SHEETS -
October 1999.
Issue Date: 13 October 1999 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-30
RAF 2000 GYROPLANE
NO. 30: •MAIN MAST;
•VNE 100 MPH;
•"OLD STYLE" CABIN ENCLOSURE;
•HORIZONTAL STABILIZER;
•PROPELLER STRIKE;
•USED ENGINE INSTALLATION;
•SET-UP of the RAF 2000 GYROPLANE
CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS.
•MAIN MAST: The main mast on the RAF 2000 Gyroplane MUST be REPLACED if the aircraft is involved in an
incident where the aircraft is rolled over, and the propeller and the rotor blades are destroyed. •TIME CHANGE
COMPONENT: The factory has established a time change factor on the MAIN MAST of 2000 hours.
•VNE: 100 MPH. The RAF 2000 Gyroplane has been approved up to 100 MPH maximum. Speeds in excess of
100 MPH are prohibited. NOTE: See speed restriction below "old style" cabin enclosure.
•"OLD STYLE" CABIN ENCLOSURE: There have been requests for use of the EJ22 or EJ25 (more horse power)
Engines on the pre 1995 models (affects serial numbers prior to and including Serial No. H2-93-4-90) of the RAF
2000 Gyroplane with the "old style" cabin enclosure (previously used the EA82 or Hirth engine installation). These
higher horse power engines are not permitted with the "old style" cabin which had a speed restriction of 70 MPH.
Do not exceed this speed under any circumstances. This notice hereby updates the temporary speed restriction
SEE: PRODUCT NOTICE NO. 11 to a PERMANENT speed restriction for the RAF 2000 Gyroplanes with the "old
style" cabin enclosure. See drawing "OLD STYLE" CABIN ENCLOSURE.
•HORIZONTAL STABILIZER: The RAF 2000 Gyroplane was tested by the factory with a Horizontal Stabilizer. It
was found to have some adverse flight characteristics evident during the testing and there was a consequential
crash of the test aircraft in 1996. Any use of a Horizontal Stabilizer is done against the recommendations and
advise of the RAF factory. The installation of a Horizontal Stabilizer does not replace the requirement for proper
and adequate flight training. Installation of the Horizontal Stabilizer is at your OWN RISK. Review HISTORY OF
THE RAF 2000 GYROPLANE'S UNIQUE DESIGN INNOVATIONS.
•PROPELLER STRIKE: Should the aircraft be involved in a roll over where the propeller is shattered the engine
must be dismantled and the crankshaft REPLACED, the rods must be magnafluxed. This is the sole responsibility
of the owner/operator.
Issue Date: 19 June 2000 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-30
RAF 2000 GYROPLANE
•USED ENGINE INSTALLATION: If the owner is using his own used engine, and performing his own engine
installation the engine must be dismantled and the crankshaft and rods must be magnafluxed.
•SET-UP of the RAF 2000 GYROPLANE: A number of owners are neglecting the most important part of the
training process and that is to have a qualified RAF Certified Flight Instructor (CFI) SET-UP their RAF 2000
GYROPLANE and fly the first hours off to ensure that the aircraft is ready for you to solo. As a student pilot,
gyroplane, you DO NOT have enough gyroplane experience to do this SET-UP on your own. For your own safety
and the preservation of your aircraft do not attempt this critical procedure without your CFI.
•NOTE: If the aircraft is not SET-UP and TEST FLOWN by the CFI the Dual Flight Instruction (DFI)
program (applies to aircraft sold after April 1999) will become NULL and VOID.
*NOTE: AIRCRAFT PRODUCT NOTICE NO. 30 •MAIN MAST; •VNE 100 MPH; •"OLD STYLE" CABIN
ENCLOSURE; •HORIZONTAL STABILIZER; •PROPELLER STRIKE; •USED ENGINE
INSTALLATION; •SET-UP of the RAF 2000 GYROPLANE. CAUTION/WARNING to all RAF 2000
GYROPLANE OWNERS.
Issue Date: 19 June 2000 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-31
RAF 2000 GYROPLANE
NO. 31: •ROTOR BLADE STORAGE and TRANSPORTATION
CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS.
Rotor blades are precision components the handling of which require care, attention, and common sense.
•ROTOR BLADE STORAGE and TRANSPORTATION: It is imperative to store the rotor blades properly when the
aircraft is not in use for extended periods of time. RAF reminds owners that rotor blades left on the aircraft with no
support for an extended period of time can lead to distortion, bending, and cracks. Rotor blades should be
supported when not in frequent use.
Care must be taken during transportation of the rotor blades. RAF reminds owners that transporting the gyroplane,
with the rotor blades left on the aircraft is not recommended.
When transporting the rotor blades on a rack, if the hub bar is left on one of the rotor blades, ensure that the hub
bar is supported so that undue stress is NOT put on the hub bar winglet, tension straps, or root end of the rotor
blade.
It has come to RAF's attention that some owners are "flinging" the rotor blades as part of the set-up of the rotor
blades. This practise MUST CEASE as this will put stress marks, scratches or could elongate the holes in the hub
bar winglets which may lead to the winglets cracking.
Continue with pre-flight and post-flight inspections as laid out in the Flight Manual and Operating Limitations Manual
and RAF 2000 Maintenance Schedule. See Section IV, 8, 9.
Add to the 100 hour inspection the following: Remove the rotor blades from the hub bar winglets and check for
scratches, stress risers, or elongation of the holes in the winglets every 100 hours of operation. Repair or replace
the winglets as required.
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 31 •ROTOR BLADE STORAGE and TRANSPORTATION,
Addition to 100 hour inspection. CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS.
Issue Date: 19 December 2000 Revision Date: 17 Aug 2011 Revision No: 002
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ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-31
RAF 2000 GYROPLANE
VALUED RAF 2000 GYROPLANE OWNER
ROTARY AIR FORCE (RAFSA) would like to bring to your attention the following VALUABLE INFORMATION:
AIRCRAFT PRODUCT NOTICE NO. 31 •ROTOR BLADE STORAGE and TRANSPORTATION. Addition to 100
hour inspection. CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS.
See the custom build sheet dated 03/00 with pricing (all prices in USD) for the following NEW PRODUCTS:
CU-140SE EJ22 TWIN FUEL PUMP CHANGE UP $100
CU-140FI EJ22 TWIN FUEL PUMP CHANGE UP FI (Fuel Injection) $190
CU-800 PRE-ROTATOR CLUTCH CHANGE UP (3 DISCS) $232
310-066-A01 TEETER STOP ASSEMBLY $75
The teeter stop assembly limits the amount of rotor blade teeter at rotor blade
RPM lower than 80. This provides additional safety in that the rotor blade to
propeller clearance is increased as per the following example:
If it is windy, or gusty when the rotors are slowing down from flight speed the
oncoming wind can catch the oncoming rotor blade and drive the retreating rotor
blade down into the propeller. This is a cause of rotor blade stiffness decreasing
as RPM decreases thus the teeter stops limit teeter movement.
160-020-S10 AXLE C/W BRAKE SHOE 1" BORE (2) $163
720-010-A06 TWIN IGNITION ASSEMBLY $1,150
Owners may have the Crank Triggered Ignition system changed up to Twin
Ignition. Owners who have purchased the CTI and would like the Twin Ignition
you must return the CTI to be changed up to the Twin Ignition. The change up
cost would be $800.
140-010-A02 FIBREGLASS FUEL/SEAT TANK (FGT) $1,500
Complete with luggage space, safety foam, fuel gauge & seat cover also includes
Revision No: 002
Issue Date: 19 December 2000 Revision Date: 17 Aug 2011
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-31
RAF 2000 GYROPLANE
070-012-A02 FGT JOYSTICK ASSEMBLY, 290-010-A02 FGT THROTTLE AND THROTTLE
LOCK ASSEMBLY, as well as 660-010-A02 FGT DUAL CONTROL, 680-010-A01
FGT FUEL SYSTEM ASSEMBLY.
Should you have any further questions please do not hesitate to call.
Issue Date: 19 December 2000 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
NO. 32: •POLYURETHANE FOAM IS FLAMMABLE (letter and specifications included)
NO. 33: •RAF ROTOR BLADES AND HUB BAR, 500 HOUR TIME CHANGE COMPONENT (formulas,
calculations, and engineering information included)
NO. 34: •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL INJECTION HOSE"
Further to the above please accept the following information:
1. DUAL FLIGHT INSTRUCTION PROGRAM (DFI), restrictions applied, was discontinued as of April 30,
2001. This program ran during the time frame of April 1999 to April 30, 2001. RAF 2000 owners that
qualified for this program will have until November 30, 2002 to complete the DFI requirements.
The DFI was instituted as a promotional and educational measure. RAF felt that it was imperative to
educate the RAF 2000 Gyroplane owners on the necessity for obtaining adequate and qualified flight
instruction. Also to obtain the final aircraft set-up and test flight from a recognized RAF 2000 Gyroplane
Certified Flight Instructor (CFI). RAF continues to STRONGLY RECOMMEND that RAF 2000 owners
obtain adequate flight instruction, and have the aircraft set-up, and test flown by a recognized CFI.
2. BONUS BUCK PROGRAM (no cash values) is discontinued as of June 30, 2001. RAF 2000 owners who
have received credits on their accounts must use this credit by November 30, 2001. After this date these
credits will be cancelled. RAF appreciates the efforts of all owners who had their RAF 2000 Gyroplane
project published!
3. RAF, after careful consideration, has decided to withdraw from the EXPERIMENTAL SPORT AVIATION
MARKET. RAF will focus its efforts on vertical markets such as agricultural, police surveillance, game
management, etc. RAF will offer, for sale, the marketing and manufacturing rights to the RAF 2000
Gyroplane, to the Experimental Sport Aviation Market, complete with molds, design specifications,
procedures, etc.
RAF will continue to offer support services and supply component parts to all RAF 2000 Gyroplane owners
and CFIs until such time as alternative support services can be developed. (See further explanation
enclosed, blue sheet).
Should you have any further questions please do not hesitate to call.
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
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Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
NO. 32: •POLYURETHANE FOAM IS FLAMMABLE
CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS with FIBREGLASS FUEL/SEAT TANK (FGT).
The FGT has been filled with POLYURETHANE FOAM supplied by Crest Foam Industries Incorporated. The foam
provides safety as it acts as an explosion suppressant. This same foam is used in race cars and jet fighters for
explosion suppressant. For more information see Web site: www.crestfoam.com.
The FGT has been filled with SG15M-1C02, G15M CLASS 2 MILL 87260. See attached letter and specifications,
(these may be enlarged for better visibility).
Crest Foam Industries Incorporated issued the following WARNING:
POLYURETHANE FOAM IS FLAMMABLE
Do not expose polyurethane foam to smoking materials, naked lights, open flames, welding, space heaters, burning
operations, other ignition sources or other heat or flames.
Once ignited, polyurethane foam will burn rapidly, releasing great heat and consuming oxygen at a high rate in an
enclosed space. Deficiency of oxygen will present a danger of suffocation to occupants. Hazardous gases and
smoke released by the burning foam can be incapacitating or fatal to human beings when exposed to sufficient
quantities.
This warning and other suitable warnings should be passed on by you to all subsequent users and ultimate
customers of products which will contain polyurethane foam.
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
Preventing catastrophic fuel vapor explosions
SafeCrest open pore reticulated polyurethane foam for explosion suppression
applications contains a network of skeletal strands with 98% void space at any pore size
The material functions essentially as a three dimensional fire
screen similar to a safety fire screen over a lighted Bunsen
burner.In a fuel tank, the empty space above the fuel level
(known as the ullage) may readily contain an explosive mixture of fuel vapor and air. It
is in this ullage area where an explosion can occur,
should it be ignited by any source.Since the liquid
fuel itself does not explode, a completely filled tank is far less likely to explode
than one that is not full.Obviously, the lower the fuel level in the tank, the
greater amount of explosive vapor present. When an
ignition source is present (perhaps from a spark),
the vapor adjacent to the spark
ignites rapidly (Figure 1). This
ignition, in turn, ignites the vapor around it, creating a "chain
reaction" as the ignition, or "flame front" gets larger and moves
faster as it propagates through the vapor (Figure 2). The rapid ignition and propagation
of the flame results in an ever growing compression wave in front of it, compressing the
unignited vapor, thus adding even greater force to an explosion (Figure 3). This sequence occurs in milliseconds.
SafeCrest prevents this chain reaction from occurring; instead, vapor ignition is confined
to the area immediately around the ignition source (Figure 4). Flame and wave
propagation are mitigated by the foam to below propagation levels (Figure 5), thus
preventing a catastrophic explosion (Figure 6).
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
Explosion Suppressant Foam
Explosion Suppressant Foam is a reticulated polyurethane foam and is used in fuel tanks where the possibility
of fuel tank explosion exists. Also known as ESF, or Safety Foam, the product was invented in the late 1960s
when the United States Air Force began using reticulated polyester polyurethane foam to suppress fires and
explosions inside fuel tanks.
Explosion Suppressant Foam has now been used for over 30 years and has found thousands of successful
applications in aircraft, boats, military vehicles, competition and emergency vehicles.
Over the years the ESF for suppression of aircraft fuel tank explosion has evolved into seven generations of
development often referred to as Type, for example Type 1 being the original polyester foam used by the USAF.
Each foam Type is qualified for all military uses. Military Specification MIL-PRF-87260A (formerly MIL-B-
83054B USAF) details the specifications for the 1 – 5 generations of conventional polyurethane foams while MIL-
DTL-83054C details the specifications for the 6 – 7 generations of electrically conductive foams.
Foam Engineers is a stockist and distributor of the SafeCrest® ESF product as manufactured by Crest Foam
Industries. Crest Foam is a leading worldwide supplier of ESF and has worked closely with the US Air Force,
Navy and Army. Foam Engineers carries in stock at all times Type 2 Yellow, Type 4 Blue and Type 6 Black
(Grade 1) Conductive grades, which can be supplied in raw block form or fabricated into any configuration to
conform inside a complex rigid or flexible bladder type fuel tank.
Once installed inside the fuel tank the reticulated polyurethane foam essentially functions as a three dimensional
fire screen. The foam is 98% void and only reduces fuel volume by 4% and adds only a negligible amount of net
weight to the fuel tank.
The benefits of ESF include: no moving parts; nothing to turn on or off; no pressure lines; no explosion sensing
devices; no functional components to fail; no failure modes if installed properly and no metal mesh to leave
filings that clog filters and injectors.
Foam Engineers has been involved in the supply of Safety Foam and the fabrication of the foam to fit inside fuel
cells for over 40 years. Crest Foam Industries is a market leading manufacturer who offers a recognized life
expectancy on their product of 10 years minimum. We also work in close association with the Combustion
Engineering Department at the University of Leeds should their explosion testing facilities be required to
demonstrate the effectiveness of the foam system.
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 4
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 5
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-32
RAF 2000 GYROPLANE
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 32 •POLYURETHANE FOAM IS FLAMMABLE.
•NOTE: CAUTION/WARNING to all RAF 2000 GYROPLANE OWNERS with FIBREGLASS FUEL/SEAT
TANK (FGT).
AIRCRAFT PRODUCT NOTICE NO. 34 •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL
INJECTION HOSE
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 6
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-33
RAF 2000 GYROPLANE
NO. 32: •POLYURETHANE FOAM IS FLAMMABLE (letter and specifications included)
NO. 33: •RAF ROTOR BLADES AND HUB BAR, 500 HOUR TIME CHANGE COMPONENT (formulas,
calculations, and engineering information included)
NO. 34: •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL INJECTION HOSE"
Further to the above please accept the following information:
1. DUAL FLIGHT INSTRUCTION PROGRAM (DFI), restrictions applied, was discontinued as of April 30,
2001. This program ran during the time frame of April 1999 to April 30, 2001. RAF 2000 owners that
qualified for this program will have until November 30, 2002 to complete the DFI requirements.
The DFI was instituted as a promotional and educational measure. RAF felt that it was imperative to
educate the RAF 2000 Gyroplane owners on the necessity for obtaining adequate and qualified flight
instruction. Also to obtain the final aircraft set-up and test flight from a recognized RAF 2000 Gyroplane
Certified Flight Instructor (CFI). RAF continues to STRONGLY RECOMMEND that RAF 2000 owners
obtain adequate flight instruction, and have the aircraft set-up, and test flown by a recognized CFI.
2. BONUS BUCK PROGRAM (no cash values) is discontinued as of June 30, 2001. RAF 2000 owners who
have received credits on their accounts must use this credit by November 30, 2001. After this date these
credits will be cancelled. RAF appreciates the efforts of all owners who had their RAF 2000 Gyroplane
project published!
3. RAF, after careful consideration, has decided to withdraw from the EXPERIMENTAL SPORT AVIATION
MARKET. RAF will focus its efforts on vertical markets such as agricultural, police surveillance, game
management, etc. RAF will offer, for sale, the marketing and manufacturing rights to the RAF 2000
Gyroplane, to the Experimental Sport Aviation Market, complete with molds, design specifications,
procedures, etc.
RAF will continue to offer support services and supply component parts to all RAF 2000 Gyroplane owners
and CFIs until such time as alternative support services can be developed. (See further explanation
enclosed, blue sheet).
Should you have any further questions please do not hesitate to call.
NO. 33: •RAF ROTOR BLADES AND HUB BAR, 500 HOUR TIME CHANGE COMPONENT
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-33
RAF 2000 GYROPLANE
A time change factor of 500 hours is being put on the rotor blades and hub bar until further notice.
Recently a RAF CFI had an incident with his rotor blades whereby he struck the ground. It was noted that the hub
bar winglet cracked. The CFI said that there was approximately 700 hours on the rotor blades and hub bar. He
subsequently sent the hub bar in for "eddy current" testing and the professors said that there were fatigue cracks
that had developed in the hub bar.
Therefore, RAF has requested from the CFI's a number of high time hub bars to be returned to the factory for
testing. Until such time as it can be determined that the above noted incident was in fact fatigue generated cracks
RAF is placing a time change factor on the rotor blades and hub bar until further notice.
RAF has worked on vibration analysis since 1995 with companies Dynamic Solutions, Vib-tech International, as
well as individuals like Mr. Jim Butler. The following calculations were the result of this intensive study.
The formulas supplied reflect a very conservative estimated life expectancy of 1925 launches for the RAF rotor
blades and hub bar. The assumption was that a launch would be followed on average by one hour of flight
operation. So each launch would consist of a cycle where the rotor blade would go from rest to tension and to rest.
It was noted that there was great discrepancy in vibration levels between aircraft. Therefore, the total expected
time was cut in half to reflect a life expectancy of 1000 hours (or 962 launches) for the rotor blade and hub bar. For
a number of years RAF has recommended verbally a time change on the rotor blades and hub bar at 1000 hours.
This again makes for some very conservative numbers of half the recommended 1925 launches to only 962
launches.
RAF uses 6061-T6 aluminum for the hub bar and the rotor blade spar and has letters of conformity to support this.
The hub bar is by far the most substantial in the experimental single and two-place gyroplane industry.
RAF respects the observations of Mr. Butler and agrees with his recommendation to put a time change factor on
the rotor blade and hub bar at 500 hours. RAF agrees with Mr. Butler's logic that RAF has no way of knowing how
much vibration is in every aircraft, nor what has been done to the aircraft or the rotor blade and hub bar in the way
of transportation, storage, or if the rotor blades have been involved in an incident.
RAF took steps to inform RAF owners by: The RAF 2000 Gyroplane Flight Manual Operating Limitations (revised
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-33
RAF 2000 GYROPLANE
1999) refers to the care and inspection procedure for the RAF rotor blades and hub bar.
Also over the last number of years, RAF has sent out numerous Product Notices specific to the rotor blades and/or
the hub bar. They are as follows:
1. PRODUCT NOTICE NO. 12, August 11, 1994 Aircraft Product Notice, RAF 2000 Gyroplane. Pre
and Post flight inspection of the Hub Bar.
2. PRODUCT NOTICE NO. 13, August 11, 1994 Mandatory Recall, RAF 2000 Gyroplane Hub bar.
3. PRODUCT NOTICE NO. 16, May 2, 1995 Rotor Blade Strikes
4. PRODUCT NOTICE NO. 18, August 24, 1995 Hub Bar Movement
5. PRODUCT NOTICE NO. 19, November 1, 1995 Improper or No Support of Rotor Blades while
Gyroplane is stored out of doors. Also contains
warning for pre and post flight inspections.
6. PRODUCT NOTICE NO. 21, October 10, 1996 Hub Bar
7. PRODUCT NOTICE NO. 23, June 16, 1997 Hub Bar Clearance
8. PRODUCT NOTICE NO. 31, December 19, 2000 Rotor Blade Storage and Transportation. Added
warning to inspect the hub bar
winglet every 100 hours.
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 33 •RAF ROTOR BLADES AND HUB BAR, 500 HOUR
TIME CHANGE COMPONENT
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-34
RAF 2000 GYROPLANE
NO. 32: •POLYURETHANE FOAM IS FLAMMABLE (letter and specifications included)
NO. 33: •RAF ROTOR BLADES AND HUB BAR, 500 HOUR TIME CHANGE COMPONENT (formulas,
calculations, and engineering information included)
NO. 34: •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL INJECTION HOSE"
Further to the above please accept the following information:
1. DUAL FLIGHT INSTRUCTION PROGRAM (DFI), restrictions applied, was discontinued as of April 30,
2001. This program ran during the time frame of April 1999 to April 30, 2001. RAF 2000 owners that
qualified for this program will have until November 30, 2002 to complete the DFI requirements.
The DFI was instituted as a promotional and educational measure. RAF felt that it was imperative to
educate the RAF 2000 Gyroplane owners on the necessity for obtaining adequate and qualified flight
instruction. Also to obtain the final aircraft set-up and test flight from a recognized RAF 2000 Gyroplane
Certified Flight Instructor (CFI). RAF continues to STRONGLY RECOMMEND that RAF 2000 owners
obtain adequate flight instruction, and have the aircraft set-up, and test flown by a recognized CFI.
2. BONUS BUCK PROGRAM (no cash values) is discontinued as of June 30, 2001. RAF 2000 owners who
have received credits on their accounts must use this credit by November 30, 2001. After this date these
credits will be cancelled. RAF appreciates the efforts of all owners who had their RAF 2000 Gyroplane
project published!
3. RAF, after careful consideration, has decided to withdraw from the EXPERIMENTAL SPORT AVIATION
MARKET. RAF will focus its efforts on vertical markets such as agricultural, police surveillance, game
management, etc. RAF will offer, for sale, the marketing and manufacturing rights to the RAF 2000
Gyroplane, to the Experimental Sport Aviation Market, complete with molds, design specifications,
procedures, etc.
RAF will continue to offer support services and supply component parts to all RAF 2000 Gyroplane owners
and CFIs until such time as alternative support services can be developed. (See further explanation
enclosed, blue sheet).
Should you have any further questions please do not hesitate to call.
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-34
RAF 2000 GYROPLANE
NO. 34: •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL INJECTION HOSE"
Fuel Injection (FI) systems require high pressure fuel line.
Inspect and ensure that the hoses attached to the FI system on your RAF 2000 Gyroplane are high pressure.
These hoses are marked (may vary) as per the following: "SAE 30R9 5/16 ID Fuel Injection Hose".
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 34 •FUEL INJECTION (FI) SYSTEMS, REQUIRE "FUEL
INJECTION HOSE"
Issue Date: 18 June 2001 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
NO. 35: •ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004)
The following preamble will inform the reader of the RAF Product Improvement of the RAF ROTOR BLADES. This
notice is to put the emphasis on the updated manufacturing process that assures consistency in the rotor blades.
Over the past 7 years RAF worked with many vibration analysis groups to explore the full operation of the RAF
gyroplane rotor blades. RAF also consulted with many helicopter and gyroplane manufacturers, as well as the
National and Saskatchewan Research Councils to study the manufacturing process as well as the operating
product in the field. The main factor was manufacturing consistency in the rotor blade sets. A close introspection
of the processes, tools, and material involved in the manufacture of the rotor blades revealed the sources of
inconsistency.
Over the past 18 months RAF entered into a vigorous development program on the RAF rotor blades. From this
product development program, RAF produced a rotor blade that is smoother, produces more consistent lift
throughout the entire flight envelop including more stability in windy turbulent conditions.
The product improvement development of the rotor blades are a result of the following:
1. PROCESS now: The RAF rotor blade airfoil remains the same using the same spar. RAF uses the same
cloth except for a 2" strip of Kevlar used as a tear resistant strip along the trailing edge. The resin is now
an Epoxy resin instead of a Vinyl-Ester resin.
2. TOOL, Rotor Blade mold/autoclave before: The previous tool was an aluminum mold machined out of 1/2"
aluminum plate, both the upper part and the bottom part of the rotor blade mold consisted of 360 aluminum
segments. These segments were bolted together. The segments would move under pressure so that the
molded component would have to be hand finished. The process to finish the blades was multi-tiered and
required hours of hand finishing and painting.
TOOL, Rotor Blade mold/autoclave now: The new tool was extruded out of a solid billet of aluminum
(eliminating the small segments and the ability for these segments to move under pressure). The rotor
blade, when removed from the tool, is polished, the parting line removed and sanded, then a 1" strip is
painted along the leading edge to cover the parting line. The rotor blade is cut to length, drilled, matched to
another rotor blade and the static set-up completed.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
TOOL, Foam Cutter now: The foam cutter and cutting table assures that the foam is cut consistently into a
precision shape to match the air foil.
3. MATERIAL before: The resin used was Vinyl Ester. Vinyl Ester resin is 30% - 60% styrene. To cure the
rotor blade the rotor blade mold/autoclave was heated to 200 causing expansion and contraction in the
tool and distortion in the molded products. Thus the rotor blade required hours of hand finishing and
painting.
MATERIAL now: The resin used is an Epoxy resin which is 100% solids. No shrinkage occurs in the
finished part. The rotor blade is cured at lower temperatures of 90 - 130. With the lower cure
temperature the tool has less expansion and contraction and thus less distortion to the part.
Continued on page 2...
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
NO. 35: •ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004)
Therefore, RAF is offering a ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004) on a one
time only basis. The RAF rotor blade owner may qualify for the ROTOR BLADE REPLACEMENT PROGRAM
based on the following:
1. Upon meeting the criteria laid out below, the improved RAF rotor blades may be purchased for $1,250
US$.
2. The owner's RAF rotor blades, complete with hub bar and tension straps, must be returned to RAF. The
owner is responsible for the shipping to and from the RAF factory. The owner is to ensure that adequate
packaging and crating are used.
3. This program applies ONLY to RAF rotor blade sets that are currently in service. Rotor blades that have
been damaged in take-off, landing, ground manoeuvres, or modified, cannot be returned for the above
replacement program.
4. The owner's hub bar and tension straps will be reused. However, RAF may determine that the hub bar and
tension straps are unusable, which will be determined upon inspection at the RAF factory. If this is the
case, one time only, the owner may purchase a new set of rotor blades with hub bar and tension straps at
retail less 20%. ($2,500 - 20% = $2,000 US$)
5. RAF requires that the owner supply a declaration as to the number of hours on the rotor blades (as per the
following). If the hours accumulated on the set of rotor blades are at 400+ RAF will change the hub bar
winglets and the associated hardware at ($180 US$). The cost of this rotor blade change up with new hub
bar winglets will be ($1,250 + 180 = $1,430 US$).
I print name do hereby certify that the Rotor Blades Serial Number
have
hours.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
Signature
6. Should the RAF rotor blade owner wish to purchase the improved RAF rotor blades without returning a set
of rotor blades the cost is $2,500 - 10% = $2,250 US$.
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 35 •ROTOR BLADE REPLACEMENT PROGRAM (expires
January 1, 2004) applies to rotor blades shipped prior to October 1, 2002.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 4
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
NO. 35: •ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004)
The following preamble will inform the reader of the RAF Product Improvement of the RAF ROTOR BLADES. This
notice is to put the emphasis on the updated manufacturing process that assures consistency in the rotor blades.
Over the past 7 years RAF worked with many vibration analysis groups to explore the full operation of the RAF
gyroplane rotor blades. RAF also consulted with many helicopter and gyroplane manufacturers, as well as the
National and Saskatchewan Research Councils to study the manufacturing process as well as the operating product in
the field. The main factor was manufacturing consistency in the rotor blade sets. A close introspection of the
processes, tools, and material involved in the manufacture of the rotor blades revealed the sources of inconsistency.
Over the past 18 months RAF entered into a vigorous development program on the RAF rotor blades. From this
product development program, RAF produced a rotor blade that is smoother, produces more consistent lift throughout
the entire flight envelop including more stability in windy turbulent conditions.
The product improvement development of the rotor blades are a result of the following:
1. PROCESS now: The RAF rotor blade airfoil remains the same using the same spar. RAF uses the same
cloth except for a 2" strip of Kevlar used as a tear resistant strip along the trailing edge. The resin is now an
Epoxy resin instead of a Vinyl-Ester resin.
2. TOOL, Rotor Blade mold/autoclave before: The previous tool was an aluminum mold machined out of 1/2"
aluminum plate, both the upper part and the bottom part of the rotor blade mold consisted of 360 aluminum
segments. These segments were bolted together. The segments would move under pressure so that the
molded component would have to be hand finished. The process to finish the blades was multi-tiered and
required hours of hand finishing and painting.
TOOL, Rotor Blade mold/autoclave now: The new tool was extruded out of a solid billet of aluminum
(eliminating the small segments and the ability for these segments to move under pressure). The rotor blade,
when removed from the tool, is polished, the parting line removed and sanded, then a 1" strip is painted along
the leading edge to cover the parting line. The rotor blade is cut to length, drilled, matched to another rotor
blade and the static set-up completed.
TOOL, Foam Cutter now: The foam cutter and cutting table assures that the foam is cut consistently into a
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
precision shape to match the air foil.
3. MATERIAL before: The resin used was Vinyl Ester. Vinyl Ester resin is 30% - 60% styrene. To cure the
rotor blade the rotor blade mold/autoclave was heated to 200 causing expansion and contraction in the tool
and distortion in the molded products. Thus the rotor blade required hours of hand finishing and painting.
MATERIAL now: The resin used is an Epoxy resin which is 100% solids. No shrinkage occurs in the finished
part. The rotor blade is cured at lower temperatures of 90 - 130. With the lower cure temperature the tool
has less expansion and contraction and thus less distortion to the part.
Continued on page 3...
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-35
RAF 2000 GYROPLANE
NO. 35: •ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004)
Therefore, RAF is offering a ROTOR BLADE REPLACEMENT PROGRAM (expires January 1, 2004) on a one time
only basis. The RAF rotor blade owner may qualify for the ROTOR BLADE REPLACEMENT PROGRAM based on
the following:
1. Upon meeting the criteria laid out below, the improved RAF rotor blades may be purchased for $1,250 US$.
2. The owner's RAF rotor blades, complete with hub bar and tension straps, must be returned to RAF. The
owner is responsible for the shipping to and from the RAF factory. The owner is to ensure that adequate
packaging and crating are used.
3. This program applies ONLY to RAF rotor blade sets that are currently in service. Rotor blades that have been
damaged in take-off, landing, ground manoeuvres, or modified, cannot be returned for the above replacement
program.
4. The owner's hub bar and tension straps will be reused. However, RAF may determine that the hub bar and
tension straps are unusable, which will be determined upon inspection at the RAF factory. If this is the case,
the owner may purchase a new set of rotor blades with hub bar and tension straps.
5. RAF requires that the owner supply a declaration as to the number of hours on the rotor blades (as per the
following). If the hours accumulated on the set of rotor blades are at 400+ a change on the hub bar winglets
and the associated hardware is required.
I print name do hereby certify that the Rotor Blades Serial Number
have hours
Signature
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 35 •ROTOR BLADE REPLACEMENT PROGRAM (expires
January 1, 2004) applies to rotor blades shipped prior to October 1, 2002.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-36
RAF 2000 GYROPLANE
NO. 36: •FRONT WHEEL POST;
•CARBURETOR BASE PLATE
•FRONT WHEEL POST
Prior to October 2002, the RAF 2000 Gyroplane Kits were supplied a front wheel post as follows: The steel post
screwed into an aluminum collar which then bolted to the upper plate. A 1/16" roll pin was inserted into the steel
post that screwed through the aluminum collar.
On occasion, owners have knocked-off, or broke the front wheel post due to excessive force to the front wheel
during landings or take-off.
RAF redesigned the front wheel post. RAF now machines the front wheel post out of a 2 1/2" steel round bar to
make it more robust. The collar and post are now one steel piece. The front wheel post is zinc dichromated.
Owners may purchase this improved post and plate.
111-011-S01 Front Post and Plate - GTX N'02 for $65 US$
•CARBURETOR BASE PLATE
The modified intake on the EJ2.2 L Subaru Engine (carburetor version) is welded. Steel tubes are welded to steel
plates for attachment to the engine. Also a steel plate is welded to the centre of these steel tubes for mounting the
carburetor.
•Caution: The weld on the carburetor base plate may crack. This condition may be caused from vibration.
If the engine idles roughly this is a possible sign that cracks may exist under the base plate of the carburetor.
To check this do the following: While the engine is idling spray WD-40 around the steel base plate where it
connects to the steel tubes. If the engine tone changes there is a crack present.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-36
RAF 2000 GYROPLANE
The Carburetor must be removed to inspect the weld around the base plate (the weld on the base plate is around
the inside oval). If cracks have occurred, the owner will have to reweld.
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 36 •FRONT WHEEL POST; applies to RAF 2000
Gyroplane kits shipped prior to October 1, 2002. •CARBURETOR BASE PLATE inspect
based on the above information.
Issue Date: 18 December 2002 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-37
RAF 2000 GYROPLANE
NO. 37: Components requiring inspection or replacement if the RAF 2000 Gyroplane is involved in
NO. 38: an incident.
Warning! 160 HP EJ2.5 SUBARU ENGINE use in the RAF 2000 Gyroplane
Further to the above please accept the following information:
RAF has replaced the Fibreglass Seat Tank (FGT introduced in 2001) with a bench style (like the FGT) rotationally
moulded Plastic Seat Tank 10/03. This Seat Tank assembly has a fibreglass seat back, which comes forward
providing luggage space. The Plastic Seat Tank is made from the same Polyethelene Resin as the “original”
Plastic Seat Tank that gave good service. The Plastic Seat Tank 10/03 is filled with the SG15M-1C02, G15M Class
2 Mill 87260 polyurethane foam. Also included is a fuel probe, sender, and gauge. RAF shipped the Plastic Seat
Tank “bench style” in October 2003. You may call RAF for more details.
RAF continues to innovate. The RAF 2000 Rotor Stabilator was first presented at EAA Airventure 2003 at
Oshkosh, Wisconsin and received the prestigious “Best New Design - Rotorcraft” Award. After an exhaustive 16-
month design and flight test program jointly conducted with Duane Hunn, Sr. (concept originator), the RAF 2000
Rotor Stabilator is now available.
RAF wanted to thank you, our many RAF 2000 owners, by offering the RAF 2000 Rotor Stabilator Conversion Kit at
the reduced introductory price of $1,500 USD. Deliveries to RAF 2000 Gyroplane owners start February 2004 on a
first-come, first-served basis.
What is the RAF 2000 Rotor Stabilator?
The RAF 2000 Rotor Stabilator is a control surface that holds the rotor at a programmed angle of attack to the
relative airflow. This control surface moves between programmed settings by the movement of an
electromechanical linear actuator. A RAF 2000 CFI will program initial flight regime settings and offer transitional
flight and ground handling training.
The location of the RAF 2000 Rotor Stabilator reduces adverse pitch moments during landing and take-off. In fact,
your RAF 2000 will have much lighter control forces in landing than before. A brochure providing more details and
pictures of the RAF 2000 Rotor Stabilator will be available for release March/April 2004.
Once the RAF 2000 Rotor Stabilator is installed, the RAF 2000 Gyroplane will fly with lower control forces and finely
trimmed altitude. The RAF 2000 Rotor Stabilator is not a replacement for flight training. NOTE: No device can
replace quality, ongoing flight and safety training.
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-37
RAF 2000 GYROPLANE
RAF has updated the RAF 2000 Gyroplane Construction Manual and Construction Videos. There are now 9
construction videos. Videos 8 and 9 are maintenance videos, which are very informative for the ongoing
maintenance of the RAF 2000 Gyroplane. These can be purchased individually.
Video Number 8 Length 80 minutes. Assembly and Maintenance of Sub-Assemblies including the Assemblies:
Gimble Head, Teeter Stop, Bendix, Pre-Rotator Clutch, Control Tube, and the Hub Bar and Rotor Blade Static Set
up. Video 8 may be purchased for: NTSC $25, $35 PAL.
Video Number 9 Length 100 minutes. EJ 2.2 Subaru Engine Component Tear-down, Installation and Maintenance
Video. Including: EJ 2.2 Subaru Engine Component Installation, Reduction Drive Installation, Pre-Rotator, Starter,
Alternator Installation, Carburetor Version, Intake and Carburetor Set-up, Fuel Injection, FI Intake, FI Set-up. Video
9 may be purchased for: NTSC $25, PAL $35.
The RAF 2000 Gyroplane Flight Manual and Operating Limitations (revision release January 2004) has been
updated to include the specifications for the EJ2.5 Subaru Engine along with the EJ2.2, and EA82 Subaru Engines.
The RAF 2000 Maintenance Schedule inspections Sheets for the 25, 50, 100, 200, and 500 have also been
updated. Owners may purchase the RAF 2000 Gyroplane Flight Manual and Operating Limitations for $30 USD
including shipping in North America.
Should you have any further questions please do not hesitate to call, RAF’s courteous staff are available to assist
you.
BE PREPARED, BE TRAINED, BE SAFE, STAY CURRENT….
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-37
RAF 2000 GYROPLANE
NO. 37: Components requiring inspection or replacement if the RAF 2000 Gyroplane is involved in
an incident.
If the aircraft is involved in an incident, the following components must be replaced and/or carefully checked. These
items include:
1. Rotor Blades c/w Hub Bar (See Product Notices 16, 19, 31, 33). For example NO. 16 lays out: The entire
Rotor Blades, Hub Bar tension straps, and hardware must be replaced where the rotor blades contact the
ground or an obstacle while in rotation. “Due to the impossibility of pinpointing the area of stress the ENTIRE
rotor system, … MUST BE COMPLETELY REPLACED.” These notices also contain time change factors.
2. Rod Ends must be changed if the aircraft is involved in an incident. Also follow the scheduled time change
recommendation (See Product Notice 23).
3. Rod Ends Check that the 8 male rod ends in the aircraft flight control system have the proper amount of
capture in control rods and the safety nuts are installed and tight.
4. Main Mast (See Product Notice #30). Main Mast must be changed if the aircraft is involved in an incident or
follow the time change recommendation.
5. Propeller Strike (See Product Notice #30). The Crankshaft must be replaced and the rods must be
magnafluxed.
6. Gimble Head Assembly must be dismantled, the components inspected, and all hardware must be replaced.
7. Torque tube must be inspected for stress indications
8. Bearing standoff must be inspected and replaced
9. Engine cradle must be inspected
10. Lateral movement blocks must be inspected, especially on bottom where the AN4 holes
11. are located.
12. Control System must be dismantled, the components inspected, and all hardware must be replaced.
13. Control System NOTE: Check that the front and rear control arms of the control tube assembly have been
drilled and safety bolted through the front and rear control tubes. Check the bell crank pivot bolt at rear of
control tube assembly, through the control arm where it attaches to the rear control yoke for proper tightness.
Check the bell crank pivot bolt at the front of the control tube assembly, through the control arm, where it
attaches to the knurled steel tube, which the joysticks attach to for proper tightness. Do not fail to check this.
This is covered in the RAF 2000 Gyroplane Construction Manual in detail.
14. Turnbuckles Check the rudder control cable turnbuckles for the proper amount of thread capture on both ends
and correct installation of safety wire. Do not fail to check this. This is covered in the RAF 2000 Gyroplane
Construction Manual in detail.
15. Reduction Drive Plate must be inspected for cracks (where the pre-rotator bracket mounts), as the cracking
may not be noted immediately.
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-37
RAF 2000 GYROPLANE
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 37 •
Components requiring inspection or replacement if the RAF 2000 Gyroplane is involved in
an incident.
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 4
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-38
RAF 2000 GYROPLANE
NO. 37: Components requiring inspection or replacement if the RAF 2000 Gyroplane is involved in
NO. 38: an incident.
Warning! 160 HP EJ2.5 SUBARU ENGINE use in the RAF 2000 Gyroplane
Further to the above please accept the following information:
RAF has replaced the Fibreglass Seat Tank (FGT introduced in 2001) with a bench style (like the FGT) rotationally
moulded Plastic Seat Tank 10/03. This Seat Tank assembly has a fibreglass seat back, which comes forward
providing luggage space. The Plastic Seat Tank is made from the same Polyethelene Resin as the “original”
Plastic Seat Tank that gave good service. The Plastic Seat Tank 10/03 is filled with the SG15M-1C02, G15M Class
2 Mill 87260 polyurethane foam. Also included is a fuel probe, sender, and gauge. RAF shipped the Plastic Seat
Tank “bench style” in October 2003. You may call RAF for more details.
RAF continues to innovate. The RAF 2000 Rotor Stabilator was first presented at EAA Airventure 2003 at
Oshkosh, Wisconsin and received the prestigious “Best New Design - Rotorcraft” Award. After an exhaustive 16-
month design and flight test program jointly conducted with Duane Hunn, Sr. (concept originator), the RAF 2000
Rotor Stabilator is now available.
RAF wanted to thank you, our many RAF 2000 owners, by offering the RAF 2000 Rotor Stabilator Conversion Kit at
the reduced introductory price of $1,500 USD. Deliveries to RAF 2000 Gyroplane owners start February 2004 on a
first-come, first-served basis.
What is the RAF 2000 Rotor Stabilator?
The RAF 2000 Rotor Stabilator is a control surface that holds the rotor at a programmed angle of attack to the
relative airflow. This control surface moves between programmed settings by the movement of an
electromechanical linear actuator. A RAF 2000 CFI will program initial flight regime settings and offer transitional
flight and ground handling training.
The location of the RAF 2000 Rotor Stabilator reduces adverse pitch moments during landing and take-off. In fact,
your RAF 2000 will have much lighter control forces in landing than before. A brochure providing more details and
pictures of the RAF 2000 Rotor Stabilator will be available for release March/April 2004.
Once the RAF 2000 Rotor Stabilator is installed, the RAF 2000 Gyroplane will fly with lower control forces and finely
trimmed altitude. The RAF 2000 Rotor Stabilator is not a replacement for flight training. NOTE: No device can
replace quality, ongoing flight and safety training.
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-38
RAF 2000 GYROPLANE
RAF has updated the RAF 2000 Gyroplane Construction Manual and Construction Videos. There are now 9
construction videos. Videos 8 and 9 are maintenance videos, which are very informative for the ongoing
maintenance of the RAF 2000 Gyroplane. These can be purchased individually.
Video Number 8 Length 80 minutes. Assembly and Maintenance of Sub-Assemblies including the Assemblies:
Gimble Head, Teeter Stop, Bendix, Pre-Rotator Clutch, Control Tube, and the Hub Bar and Rotor Blade Static Set
up. Video 8 may be purchased for: NTSC $25, $35 PAL.
Video Number 9 Length 100 minutes. EJ 2.2 Subaru Engine Component Tear-down, Installation and Maintenance
Video. Including: EJ 2.2 Subaru Engine Component Installation, Reduction Drive Installation, Pre-Rotator, Starter,
Alternator Installation, Carburetor Version, Intake and Carburetor Set-up, Fuel Injection, FI Intake, FI Set-up. Video
9 may be purchased for: NTSC $25, PAL $35.
The RAF 2000 Gyroplane Flight Manual and Operating Limitations (revision release January 2004) has been
updated to include the specifications for the EJ2.5 Subaru Engine along with the EJ2.2, and EA82 Subaru Engines.
The RAF 2000 Maintenance Schedule inspections Sheets for the 25, 50, 100, 200, and 500 have also been
updated. Owners may purchase the RAF 2000 Gyroplane Flight Manual and Operating Limitations for $30 USD
including shipping in North America.
Should you have any further questions please do not hesitate to call, RAF’s courteous staff are available to assist
you.
BE PREPARED, BE TRAINED, BE SAFE, STAY CURRENT….
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-38
RAF 2000 GYROPLANE
NO. 38: Warning! 160 HP EJ2.5 SUBARU ENGINE use in the RAF 2000 Gyroplane
Note: This Warning does not apply to RAF 2000 gyroplane pilots with 400+ hours on the RAF 2000 Gyroplane. A
qualified RAF 2000 Gyroplane CFI should provide transitional training for all gyroplane pilots that wish to install this
160 HP EJ2.5 Subaru Engine on the RAF 2000 Gyroplane.
160 HP EJ2.5 Subaru Engine This engine is not recommended for use in the RAF 2000 Gyroplane for normal
operation.
The 160 HP EJ2.5 Subaru Engine should only be installed on the RAF 2000 Gyroplane because of special
applications. Special applications are as follows: heavy load, (crop dusting, pilot weight, special projects) high-
density altitude etc.
RAF 2000 Gyroplane owners, using the 160 HP EJ2.5 Subaru Engine, in order to become competent to handle
the additional power and thrust, must obtain additional flight and ground handling training.
•NOTE: AIRCRAFT PRODUCT NOTICE NO. 38 •
Warning! 160 HP EJ2.5 SUBARU ENGINE use in the RAF 2000 Gyroplane
Issue Date: 15 December 2003 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-39
RAF 2000 GYROPLANE
NO. 39: Hub Bar Winglets, and AN12 Bolt
Several Hub Bar Winglets have developed cracks due to extenuating circumstances beyond RAF’s control.
Some have questioned the Hub Bar Winglet’s strength. Also during an incident one of the AN12 Bolts suffered
a catastrophic failure at the head. The AN12 Bolt had sustained a number of abnormal stress loads beyond
RAF’s control. The following mathematical formulas give the specifications in detail for these questioned
components:
Centrifugal loading x M (in lbs.) x R (in inches) x (RPM)² x K
x 48 x 73 x (340)² x 0.00002850
F (in lbs.) = G
F (lbs.) = 1
F (lbs.) = 11470.9 lbs
Stress 11470.9 = 5.735 kpsi
2 sq. in.
S (psi) = F (lbs.) =
A (inch)²
In addition, add the stress of the Hub Bar as a result of the bending moment created by the lift at each end
transposed to the centre. This stress is represented by:
(M/2) x G x L = 3M x G x L / (W2 x A)
(W2/6) x A
Take the weight of the aircraft to figure the stress caused by the weight resisting centrifugal loading use the
following s = 3MxGxL/ WxWxA. Where S stress due to bending of the Hub Bar in psi.
M = mass of the gyroplane
G = Loading Factor
L = Half the length of the Hub Bar (20.25 inches)
W= thickness (1 inch)
A = is the width of the Hub Bar (2 inches)
The aircraft weight approximately 1320 lbs. the stress is 3960 psi. The total stress is 8.755 kpsi = 5.735+3.960
kpsi. The yield stress for 6061-T6 Aluminium is 44 kpsi so there is a safety factor of (44/8.755) = 5.
The forgoing preamble is to establish the current strength and methodology used. What follows are the steps
taken by RAF to further increase the safety factor of the already generous margins with this item.
Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 1
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-39
RAF 2000 GYROPLANE
The AN12-34A Bolt is rated at 50,000 psi with an expected load of 11,470.9 psi this is a 4 times safety factor.
RAF is introducing the following improvements:
A new RAF NAS bolt where the radius under the head is twice as large as the normal NAS bolt, the installation
of a washer with the proper bevel cut to accommodate this radius. This new bolt will increase the strength by
25%.
RAF recently purchased a new software program for contour machining. The Winglets and Hub Bar are being
machined to eliminate the straight cuts on the top and bottom using the process of contour machining. See
following page for picture of Hub Bar Winglets and Bolt.
Continued…
Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 2
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-39
RAF 2000 GYROPLANE
NO. 39: Hub Bar, Winglets, and AN12 Bolt Area of
Enlargement
Nut Part Number
MS17825-12
New Washer Part Number
MS20002C12
Improved
Contour
New Bolt Part Number
NAS RAF 501-012
The Winglets have been made ½” (.50) wider to give and extra ¼“ (.250) between the mounting bolts on
the outside edge.
RAF is offering a replacement program for 1 year (January 1, 2005 – December 31, 2005) to RAF rotor blade
owners. The following:
1. Hub Bar Winglets and NAS RAF 501-012 Bolts $300, FOB RAF.
2. Hub Bar, Winglets, and NAS RAF 501-012 Bolts $550, FOB RAF.
3. Cord Block, Adjusters and associated hardware extra, FOB RAF.
In order to qualify:
1. The complete Hub Bar and Winglets must be returned to RAF.
2. The Rotor Blade owner must pay shipping for the returning Hub Bar and Winglets to RAF as well as
shipping for the replacement Hub Bar and Winglets.
3. The Rotor Blades c/w Hub Bar must not have been involved in any incident such as Rotor Blade flapping,
or a Rotor Blade strike to qualify. Upon inspection, RAF may determine the parts are unusable if this is the
case the RAF Rotor Blade owner will be contacted.
4. RAF requires the owner sign a declaration as to the number of hours on the Rotor Blade Hub Bar and
Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 3
ROTARY AIR FORCE SA PTY LTD ROTARY AIR FORCE SA PTY LTD
PO Box 2071, Upington, 8800 Hanger 3
South Africa Upington International Airport
Tel: +27 54 331 3534
Fax +27 54 332 3628 Upington, 8801
Email: [email protected] VAT Reg No: 4230236772
Web: www.rafsa.co.za Company Reg No: 2007/012378/07
Emergency: 0833758841
ROTARY AIR FORCE
PRODUCT NOTICE REF: C/PRONOT.RAF-39
RAF 2000 GYROPLANE
Winglets (as per the following).
I (print name) do hereby certify that Rotor Blades c/w Hub
Bar Serial Number have hours. I further certify
that the aforementioned product has not been involved in an incident.
Signature
• NOTE: AIRCRAFT PRODUCT NOTICE NO. 39 • Hub Bar, Winglets, and AN12 Bolt in the RAF 2000
Gyroplane. SEE ALSO PRODUCT NOTICES 16, 19, 31, 33 and 37(1).
Issue Date: March 1992 Revision Date: 17 Aug 2011 Revision No: 002
Page 4
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