Full-Scale Transition
By Tom Ryan
Introduction
Transitioning from flying model RC helicopters to full-scale helicopters is no small feat. Chuck Bucci of Hales Corners, Wisconsin, took that challenge on when he bought a Rotorway 162F kit helicopter in October 2010 and began building it in his garage. By January 21, 2011—only four months later—the kit was 95% complete and only hours of work away from its maiden flight.
From Model Helis to Full-Scale
Chuck’s interest in full-scale helicopters grew naturally from building and flying model helicopters such as his T-Rex 600 and from seeing a friend’s experimental Rotorway Exec. Because he already understood rotorcraft aerodynamics from model aviation, moving to a full-scale kit felt like a logical next step rather than a leap into the unknown.
Making the Decision
This was not a spur-of-the-moment decision. Before committing to the project, Chuck took eight hours of lessons in a Rotorway to confirm that flying one was what he wanted. He also involved his wife, Andrea—he wanted her to share the experience. Andrea rode in a Rotorway, agreed to be part of the project, served as his copilot, and spent many hours helping.
Chuck visited the Rotorway factory in Arizona to see how the kits were made and to speak with the people he would be dealing with during the build. After the tour he felt confident that the Rotorway was the right choice for a first-time builder.
Support and Resources
To avoid the common fate of abandoned kits, Chuck sought community support and advice:
- He joined the Rotorway Owners Group and the Experimental Aircraft Association (EAA).
- Members of both organizations shared experiences and building techniques that proved helpful.
- A local, experienced Rotorway builder assisted with advice and oversight during the project.
Chuck’s background also helped: he had been a self-employed electrical contractor for roughly 35 years and kept a basement full of metalworking machine tools. He used those tools to make parts for the helicopter, saving time and money and reducing the need for outsourcing.
Finding a Kit and the Build
After research and networking, Chuck found a Rotorway kit in Florida that had been purchased new but never assembled. He and a local experienced builder inspected the kit, confirmed it met his needs, and purchased it. The kit was transported to Wisconsin in a rented truck, and the build progressed rapidly in Chuck’s garage.
Chuck set realistic expectations for time and cost, and he committed to an intensive eight-month schedule rather than letting the project drag on. He said, “You have to have the time and money to put into this; otherwise you’re just fooling yourself.”
Timeline and Cost
- Start: October 2010 (kit purchased)
- By January 21, 2011: kit 95% complete
- Target completion: Summer 2011 (Chuck planned a continuous push to finish in eight months)
- Cost estimate: approximately $60,000 (not including the cost of obtaining a pilot’s license)
Chuck believed $60,000 was a reasonable investment for a quality, two-seat personal helicopter. Being both builder and mechanic would reduce ongoing maintenance costs compared with factory-built helicopters, and operating costs such as fuel per hour would be lower.
From Model Clubs to Full-Scale Flying
Chuck’s six-year affiliation with the Southeast Wisconsin Area Rotary Modelers (SWARM) RC helicopter club in Franklin, Wisconsin, helped foster his love of helicopters. The pathway from model aviation (AMA) to full-scale flying (EAA) illustrates a natural transition many hobbyists make. The partnership between model and full-scale communities benefits everyone who loves aviation—the thrill of flight is the common denominator.
First Flight and After
Chuck’s build-and-fly dream was realized on April 12 (well ahead of schedule). Since then, he continues to enjoy both model and full-scale flying.
Sources
Rotorway International
- Phone: (480) 961-1001
- Website: www.rotorway.com
Transcribed from original scans by AI. Minor OCR errors may remain.
