HORNET

Sport Gyroplane Documentation

6
Advanced Composites

For reference only!

Not to be used as a set of plans
for the construction of an
aircraft, in whole or part.
Information contained within this
document is subject to change
without notice. Holder of this
document claims all
responsibilities.

This document created and provided by

Donald T. Shoebridge
donshoebridge@gdt-systems.com

Copyright 2000-2007
All Rights Reserved
Forwww.gdt-system.com
 HORNET Copyright 2003-2006 Donald T. Shoebridge All Rights Reserved Release 14

IT IS IN YOUR BEST INTEREST TO READ THIS PAGE

1. Safety Notice
This document It is being freely provided to the aviation community, and is intended to convey the design progression of the Hornet Sport Gyroplane. Future updates of this document may include the construction of
the prototype Hornet.
THIS DOCUMENT IS NOT PROMOTED OR DISTRIBUTED AS A SET OF CONSTRUCTION PLANS AND I DO NOT ENCOURAGE THE BUILDING OF AN AIRCRAFT USING THIS DOCUMENT, IN WHOLE OR
IN PART. ANYONE WHO UNDERTAKES THE BUILDING OF AN AIRCRAFT USING THIS DOCUMENT DOES SO AT HIS OR HER OWN RISK!
If you choose to use this document as the basis for the construction of an actual aircraft, you should be aware of the following;
1. I have no training or professional credentials in the area of aircraft design or construction,
2. Although I have made a reasonable effort to make this document as complete and accurate as possible, this document may contain errors or omissions that may result in; wasted time and materials, an
aircraft with undesirable flying characteristics, an aircraft that is not structurally or mechanically sound, which can cause you financial loss, physical injury, or death!
3. Because the Hornet prototype has not yet been built or flown, it has not been certified by any aviation regulatory or safety agency.
4. Other than regular inspections and/or testing, there is no means to predict the operational lifetime of the various structural components.
THIS DOCUMENT AND ALL INFORMATION CONTAINED, IS BEING PROVIDED "AS IS", WITHOUT ANY EXPRESS OR IMPLIED WARRANTY. THE AUTHORS OF THIS DOCUMENT MAKE NO
REPRESENTATION OR WARRANTY OF ANY KIND CONCERNING THE ACCURACY OR COMPLETENESS OF THIS DOCUMENT, OR ITS FITNESS FOR ANY PARTICULAR PURPOSE.
ATTEMPTING TO FLY AN AIRCRAFT WITHOUT FIRST COMPLETING A FLIGHT INSTRUCTION PROGRAM WITH A QUALIFIED FLIGHT INSTRUCTOR, TO INCLUDE SOLO FLIGHT AUTHORIZATION, CAN
CAUSE YOU FINANCIAL LOSS, PHYSICAL INJURY, OR DEATH! FOR THE BENEFIT OF YOURSELF AND OTHERS, SEEK PROFESSIONAL FLIGHT INSTRUCTION BEFORE ATTEMPTING TO PILOT AN
AIRCRAFT!

2. Copyright Notice And Terms Of Use

Although the text and drawings contained in this document are being made available for distribution without charge, U.S. and international copyright statutes protect the materials contained in this document.
Provided that the Safety Notice, Copyright Notice and Terms Of Use pages of this document are included, permission is hereby granted for the following;
1. You may create any number of copies, in any medium for your own personal use,
2. You may distribute copies of this document to others, so long as no fees are levied,
The copyright holder, Donald T. Shoebridge, reserves all other rights under the copyright statutes. Under the terms of this copyright;
1. You may not charge a fee for the distribution of this document,
2. You may not incorporate any copyrighted material, in whole or in part, into any commercial work or project without the express written permission of the copyright holder,
3. You may not make any modifications, deletions, or additions to this document,
4. Infringement may subject you to both civil and criminal liability.
NOTICE: I WILL PURSUE, WITH EXTREME PREJUDICE, ALL CASES WHERE THE ABOVE PROVISIONS APPEAR TO HAVE BEEN VIOLATED!

1.2.2
HORNET Copyright 2003-2006 Donald T. Shoebridge All Rights Reserved Release 14

1.3.3
 .500 12.70

.500 12.70

SECTION A-A

1.500 38.10
1.500 38.10

3.500 88.90

2.469 62.71

1.750 44.45 A

1.031 26.19 A
2.400 60.96
.257 6.53

0 0

.875 22.23

FOR ACCURACY REASONS, ALL

HOLES THROUGH THIS PART SHOULD
BE MARKED AND TRANSFERED FROM
THE KEEL TUBE AFTER ASSEMBLY OF
HORIZONTAL STABILIZER HAS BEEN
COMPLETED.
4.000 101.60

4.750 120.65
0 0

1.500 38.10

P/N
72-00008
TITLE
VERTICAL STABILIZER PASS THRU
MTRL
WOOD, PINE
HEAT TREAT

FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
D
 FOR ACCURACY REASONS, ALL
HOLES THROUGH THIS PART SHOULD
BE MARKED AND TRANSFERED FROM

1.000

2.000
THE KEEL TUBE AFTER ASSEMBLY OF
HORIZONTAL STABILIZER HAS BEEN
COMPLETED.

0
.500

1.031

.257

2.469

3.500
.875
1.500

46-00001 HARDPOINT PLUG

P/N TITLE

PART GROUP
46 - Wood and Paper Products

hornet
DIMENSIONS AND TOLERENCES
UNLESS OTHERWISE SPECIFIED
LINEAR ANGULAR ALL DIMENSIONS ARE IN
X.XX .01
X.XXX
X
.005 X.X
0.5
0.1 INCHES [MM]
X.XXXX .0001
FILENAME
D:\CadWork\Drawings\46\46-00001 - HardpointPlug.SLDDRW
DO NOT SCALE DRAWING SolidWorks
CREATED WITH REV
- THIRD ANGLE
MTRL
WOOD, PINE ENG
D. SHOEBRIDGE SCALE
1:1 SIZE
B
HEAT TREAT APRV DATE

Printed on Saturday, November 08, 2008 FINISH DETAIL SHEET

1 OF 1
 R1.50 38.1

28.25 717.6

31.75 806.5

60.00 1524
0 0
27.32 693.9 30° REF.

20.50 520.7

10.50 266.7
R1.50 38.1
10.00 254

6.00 152.4

0 0
1.50 38.1

R.75 19.1 R1.50 38.1

65-00007 HORIZONTAL STABILIZER CORE

P/N TITLE

PART GROUP
65 - Wind and Air Control (Fans, Propellers, Vanes, Wings, Ducting, etc.)
DIMENSIONS AND TOLERENCES

hornet
UNLESS OTHERWISE SPECIFIED
LINEAR ANGULAR ALL DIMENSIONS ARE IN
X.XX
X.XXX
.01 X
.005 X.X
0.5
0.1
INCHES
X.XXXX .0001
FILENAME
D:\CadWork\Drawings\65\65-00007 - HorizontalStabilizer.SLDDRW
DO NOT SCALE DRAWING SolidWorks
CREATED WITH REV
-
MTRL
STYROFOAM, 2 LB/ CU. FT ENG
D. SHOEBRIDGE SCALE
1:3 SIZE
D
HEAT TREAT APRV DATE

Printed on Saturday, November 08, 2008

FINISH DETAIL SHEET
1 OF 1
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 65-00007 HORIZONTAL STABILIZER CORE
2 1 72-00008 VERTICAL STABILIZER PASS THRU
3 1 46-00001 HARDPOINT PLUG

NOTES: UNLESS OTHERWISE SPECIFIED

1. BOND IN HARDPOINT PLUG USING FLOX AND EPOXY JUST PRIOR TO
COVERING FOAM WITH KEVLAR/FIBERGLASS AND EPOXY.
65-00006 HORIZONTAL STABILIZER
P/N TITLE
2. HARDPOINT PLUGS MUST BE FLUSH OR SLIGHTLY BELOW FLUSH WITH PART GROUP
FOAM CORE SURFACE. USE FLOX AS A FILLER TO MAKE AREA 65 - Wind and Air Control (Fans, Propellers, Vanes, Wings, Ducting, etc.)
OVER PLUG FLUSH WITH FOAM SURFACE IF NECESSARY. DIMENSIONS AND TOLERENCES

hornet
UNLESS OTHERWISE SPECIFIED
LINEAR ANGULAR ALL DIMENSIONS ARE IN
X.XX
X.XXX
.01 X
.005 X.X
0.5 INCHES [MM]
0.1
X.XXXX .0001
FILENAME
D:\CadWork\Drawings\65\65-00006 - HorizontalStabilizer.SLDDRW
DO NOT SCALE DRAWING SolidWorks
CREATED WITH REV
-
MTRL
- ENG
D. SHOEBRIDGE SCALE
1:2.5 SIZE
D
HEAT TREAT APRV DATE

Printed on Saturday, November 08, 2008

FINISH DETAIL SHEET
1 OF 1
 34.25 870

R.75 19.1
R14.6 369.9 REF

R.25 6.4

SECTION A-A

SECTION B-B

A
B

A B

4.00 101.6

14.00 355.6

12.50 317.5

60° REF.

75° REF.

1.50 38.1 P/N

65-00011
TITLE
VERTICAL STABILIZER FOAM CORE
MTRL
STYROFOAM, 2 LB/ CU. FT
HEAT TREAT
0 0
FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

R.50 12.7 1.50 38.1 LINEAR
X.XX .01 ANGULAR
IN [MM]

42.00 1066.8
0 0

18.74 476
16.18 410.9

17.61 447.4

19.77 502.3
20.18 512.5

32.82 833.7

X.XXX .005 X 0.5

X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:2
REV
-
SIZE
D
 .750 19.05 REF. .750 19.05 REF.

.257 6.53 2 PLACES

DRILL HOLES AFTER
ASSEMBLY WITHIN
VERTICAL STAB

14.00 355.60

.058 1.47

1.125 28.58
P/N
70-00075
TITLE
V-STAB MOUNT TUBE
MTRL
STEEL, 4130
HEAT TREAT

FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
B
 2.00 50.80

.75 19.05

+.02 +0.51
1.13 28.58
- .00 0
R.50 12.70 .26 6.53
BLEND WITH V-STAB DRILL AFTER ASSEMBLY
FOAM CORE WITHIN VERTICAL STAB

1.50 38.10
.75 19.05

P/N
46-00004
TITLE
2.00 50.80 V-STAB HARD POINT - LOWER
1.50 38.10 MTRL
WOOD, PINE
4.00 101.60 HEAT TREAT

FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
B
 2.00 50.80

.75 19.05

+.02 +0.51
1.13 28.58
- .00 0
.26 6.53
DRILL AFTER ASSEMBLY
WITHIN VERTICAL STAB

1.50 38.10

.75 19.05

P/N
46-00003
TITLE
1.50 38.10 2.00 50.80 V-STAB HARD POINT - UPPER
MTRL
WOOD, PINE
HEAT TREAT
4.00 101.60
FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
B
ITEM NO. QTY. PART NO. DESCRIPTION
1 1 65-00011 VERTICAL STABILIZER FOAM CORE
2 1 46-00003 V-STAB HARD POINT - UPPER
3 1 46-00004 V-STAB HARD POINT - LOWER
4 1 70-00075 V-STAB MOUNT TUBE
5 2 V-STAB FOAM FILLER

DRILL HOLE THRU ALL PARTS AFTER

THIS ASSEMBLY HAS BEEN COVERED
BOTH ENDS

BLEND RADIUS OF BLOCK

TO MATCH RADIUS OF FOAM

P/N
75-00003
TITLE
VERTICAL STAB
MTRL
-
HEAT TREAT

FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
D
 19.188

18.438

5.938

0
.257 ~ 2 PLACES
SPOT DRILL FINAL LOCATION OF
THESE HOLES USING COMPLETED
VERTICAL STAB ASSEMBLY.

.375
0
1.000

P/N
72-00007
TITLE
.058 VERTICAL STABILIZER PIVOT TUBE
.257 MTRL
STEEL, 4130
90 ORIENTATION OF THIS HEAT TREAT

FINISH
HOLE CRITICAL TO VERTICAL
STAB MOUNTING HOLES IN DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED
LINEAR
ABOVE VIEW. X.XX .01 ANGULAR
IN [MM]
X.XXX .005 X 0.5
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
B
 +.000 0
1.375 34.93
- .035 - 0.89
+.020 +0.51
1.500 38.10
- .000 0

+.010 +0.25
1.025 26.04
- .010 - 0.25

P/N
72-00009
TITLE
VERTICAL STABILIZER PIVOT TUBE SPACER
MTRL
ACETAL (POM, DELRIN)
HEAT TREAT

FINISH

DIMS AND TOLERENCES UNLESS OTHERWISE SPECIFIED

LINEAR
X.XX
X.XXX
.01 ANGULAR
.005 X 0.5 IN [MM]
X.XXXX .0001 X.X 0.1
ENG
D. SHOEBRIDGE THIRD ANGLE
APRV

DETAIL SHEET
1 OF 1
SCALE
1:1
REV
-
SIZE
B