You are not really embarked on a true aircraft construction project until you start spending serious cash. We already had a suitable engine (a Rotax SC 503), a Brock stick assembly, a LEAF throttle quadrant, and I was working on a new Digipod instrument pod, so we really had a good start. To transition from a good start to well-on-our-way required that we do some serious spending!

 Star Bee Gyros

The basic and most comprehensive item from Star Bee was the drilled rolling airframe kit ($2,338.00). This is a great bargain considering that all the tubing and angle stock is CNC cut and drilled and all hardware is included. The kit is designed to take you through Phase 13 and includes a Black Beauty rotor head, the seat, all wheels and associated hardware, and the fuel tank.

To round things out, we ordered the seat cushion/cover (#876 at $15.00),  the Star Bee tail (#895 at $575.00), and the Wunderlich prerotator (#905 at $767.00). In short, for about $3700 we should have most of the serious components. Since Dana and Laura were going to be exhibiting at Mentone, we opted to take deliver there.

Rotor Flight Dynamics

Given cost, availability, performance, and the fact that we planned to use a prerotator, a set of Ernie Boyette's Dragon Wings blades (24 foot rotor disc/$1500.00) were ordered, also for delivery at Mentone.

What We Got at Mentone

I have known Ernie and the way he does business for many years now and I was never in any doubt about the quality of what I would be picking up. In fact, the  Dragon Wings blades were built to his superb standard of quality and finish - good stuff!

I had heard nothing but good things about the way Dana and Laura run  Star Bee Gyros , but you still hold your breath when ou have sent off a significant amount of cash in your first transaction with a company.

To make a long story short, I need not have worried. The tail components and fuel tank were back-ordered - no problem - but everything else was just perfect. All tubes, plates, and angles were wrapped and labeled, hardware was carefuly bagged by phase, and everything was top quality. The finish on all cuts and holes was simply first-rate!

One of the biggest issues when buying your airframe materials is whether the supplier is actually delivering the material in the alloys specified. Star Bee keeps the factory dye labels on all pieces - no doubt that you are getting what you need. Even if you are going to build from scratch, their raw materials kits should relieve you of any doubts about the use of the proper materials.

 Finishing

We wanted this project to be on the fast-track, so we did not intend to spend a lot of time painting aluminum. Within 24 hours of getting the material home, we had it off to a local anodizing shop for a clear-satin treatment. It cost us just $170 for all tubes, angles, and plates and eliminated the burdensome job of painting each piece. BIG PLUS!

Shown below is a resonably accurate tally of the various costs associated with assembling the new bird. This will be a rolling total so expect the figures to change as the project progresses.