As with anything...

I feel that my biggest mistake was assuming anyone could build, operate
and maintain a kit helicopter. I was wrong there, very few can do so,
even with the certified helicopters. Our assembly manual was excellent.
Very nice exploded drawings, pictures and step by step instructions. The
common mistake that about 90% of the Mini-500 builders made was the
same; they didn't read the instructions and only followed the drawings
and pictures. Believe it or not, but true. This lead to many common
mistakes, from not heating the parts before installation to missing
parts. I can't tell you how many times an owner would come to the
factory with his Mini-500 for the free inspection we offered, only to
hold out his hand and ask why he had extra parts, and always after he
had 40 hours of flight time on his Mini-500. They most all came to the
factory after something was going wrong, and it was always a simple
overlooked procedure or something assembled wrong, and always after they
flew it until it broke. Some aircraft were so far out of balance that
they shock themselves apart in only 40 hours, and only because the
builder didn't bother to balance it, or did it wrong and ignored the
fact that he did it wrong.

== This is probably true of all kit a/c, it's just more critical in
helicopters. I
follow the Rotorway forums and they have the same problem with
their kits.


What would I have done differently using hindsight? I would have tripled
the price of the Mini-500 and sold much less of them to people that can
actually afford to own a helicopter, and built it under our complete
supervision. Then I could have had a much smaller factory with less
overhead, and fewer customers that would have paid more, and maintenance
or improvement costs would have not mattered to them so much, because
they could afford it, like in the commercial aircraft field. It would
have just been too bad for someone that wanted a helicopter but couldn't
afford one, which the Mini-500 did fit the bill.

== Price seems to be directly related to helicopter accidents. When the
Robinson
R22 first came out untrained pilots could suddenly afford a helicpter.
R22s were raining from the sky before Robinson started mandating proper
training.

Back in 1990, when I first started the Mini-500 project, there was only
one engine manufacturer that could provide 5 engines "new-in-the-box a
week", that had a performance history, and had service all around the
world. That was Rotax. The Mini-500 was designed around the 582 Rotax
engine. There was nothing else available. That is still as true today as
15 years ago.

The 582 Rotax is a good choice for the Mini-500. It has the power
necessary to do the job, at the price people will pay. The engine was
only ran at 6600 RPM's, which is still a 100% duty cycle for the engine
at 70% power reduction. Remember, the same engine in the snowmobile
industry will produce 110 hp at 8500 rpm's. Rotax simply derated the
engine for aircraft by lowering the RPM's. If you look at the power
charts of the snowmobile, the output HP at 6500 rpm is 64HP. No Rotax in
a Mini-500 has ever failed due to overexertion, if operated properly.
Only to improper installation or improper (or lack of) maintenance. It
is the finest light-aircraft engine ever made.

Also in the light-aircraft industry, 98% of all Rotax failures are due
to poor installation or inadequate maintenance. If you want a
bulletproof idiot-proof engine, buy an O-200.

The Rotax was, and is still the only choice of engine for the Mini-500
size helicopter, for the price people want to afford. Some people have
tried to replace the engine with something else, and all have failed.
Even the Solar APU engines will never work as intended. They burn more
fuel than you can carry, have no explosion proof protection, and the low
duty cycle makes them burn out quickly. They are not turbine engines,
they are merely self-propelled turbochargers meant to power generators
and pumps. To this day no one has been successful, except me with the
Rotax engine.

== Rotax is the engine of choice for most Ultralights and it performs well
and
reliably as long as it's installed and maintained properly. Would I
personally
fly with one in a light helicopter? Probably not, but that's just me.