Top: The saying “measure twice and cut once” is useful no
matter the size of your project. In this case, it’s a full-scale
Rotorway Exec 162F helicopter.
Above: The Exec 162F is a two-seat helicopter, which is a
good thing since Chuck’s wife, Andrea, enjoys flying as well.
The heli has a maximum takeoff weight of 1,500 pounds and a
rotor diameter of 25 feet.
TRANSITIONING FROM flying model RC
helicopters to full-scale helis is no small feat, but
Chuck Bucci from Hales Corners, Wisconsin,
took on that challenge. Chuck bought a
Rotorway 162 F (kit helicopter) in October of
2010 and began building it in his garage. On January 21,
2011, only four short months later, the kit was 95% complete
and only hours of work away from its maiden flight.
After building and flying model helicopters, such as his
T-Rex 600, and after seeing a friend’s experimental
Rotorway Exec, Chuck decided that he wanted to build and
fly his own full-scale helicopter.
Right: The finished helicopter
in flight.
Clockwise from below: Various photos of the Rotorway during its
assembly in Chuck’s garage. His goal was to complete the project
in eight months.
December 2011 41
After many hours of research and networking
with others who have built Rotorway helicopters,
Chuck found a kit in Florida that had been
purchased from Rotorway but never built. The
owners of the kit didn’t have the time to build the
helicopter and decided to sell it.
An experienced local builder, who also
happened to own a Rotorway, offered his help and
the two set off for Florida to inspect the kit and
make sure that it was what Chuck wanted. The
asking price was within Chuck’s budget, but he
also had to consider the cost of the upgrades that
the helicopter would need.
After a careful inspection of the kit, the deal
was made and the Rotorway kit was on its way to
Wisconsin in a rented truck. Chuck’s transition into
full-scale experimental helicopters had begun.
This wasn’t a quick decision. Before Chuck
shelled out the money for the project, he did
something that many transition builders don’t do:
he took some lessons in a Rotorway. He took
lessons for eight hours, making sure that this was
what he wanted to do.
After flying the Rotorway 162F, he was ready to
go ahead with the project, but first things first! His
wife, Andrea, had to buy into the whole idea, too;
after all, this was a big commitment of time and
resources. Chuck wanted her to be a part of the
process, so Andrea took a ride in a Rotorway so she
could see where he wanted to go with his building
and flying. He wanted her to agree that this was a
good idea and that it would be a fun experience for
both of them. Andrea agreed and served as is his
copilot on the project and spent many hours
helping.
Chuck also visited the Rotorway factory in
Arizona to talk to the people with whom he would
be dealing during his build. He wanted to see where
the kits were made and what went into the
materials.
With his tour complete, Chuck felt confident
that the Rotorway was the best helicopter out there
for him as a first-time builder. Many like the idea
of building, but after they buy a kit and start the
work, the reality of the long hours and extra
resources needed hit home. Often, the kit doesn’t
get started because of lack of time and skills, and in
the end, it gets sold.
To ensure that wouldn’t be the case, Chuck
joined the Rotorway Owners Group and the EAA to
get the best advice. Members of both organizations
shared experiences and building techniques and
were helpful to Chuck during the build. A local
builder also assisted him with advice and checked to
make sure the build went as planned.
Building a full-scale helicopter such as the
Rotorway takes time, money, and a reasonable
amount of mechanical experience. Chuck has been
a self-employed electrical contractor for roughly 35
years. He has a basement full of metal-working
machine tools that he used to create parts for the
helicopter, saving him time and money and
eliminating the need for outside contractors.
Chuck had reasonable expectations of what it
would take to complete the build, plus the time and
cost to earn a pilot’s license. He and Andrea felt
that his timetable seemed realistic and acceptable,
and he wasn’t worried about losing interest in the
overwhelming work needed to complete the build
in the eight months he allotted.
Summer 2011 was set as the target completion
date. To Chuck, this wasn’t going to be a work in
progress, dragging on for years and years; it
would be an ongoing push every day until the
helicopter was complete.
When asked what he believed it would take to
do the build right and complete it in the eight
months he forecasted, he replied, “You have to
have the time and money to put into this;
otherwise you’re just fooling yourself.”
All right, we know the timeline was eight
months, but what about the cost?
Chuck believed he would invest $60,000 in the
helicopter, and that’s not counting the cost of
getting his pilot’s license. Considering what
helicopters sell for today, he believes that’s a low
price for a quality helicopter. Because he’s both
the builder and the mechanic, maintenance costs
would be lower compared to paying an A&P
aircraft mechanic to do the inspections and needed
repairs. Also, the cost per hour in fuel is a fraction
of that of a factory-built production helicopter.
All things considered, the Rotorway is a costefficient,
two-seat personal helicopter that is
affordable for the average builder.
At the age of 57, Chuck, who came to love
helicopters because of his six-year affiliation
with the Southeast Wisconsin Area Rotory
Modelers (SWARM) RC helicopter club in
Franklin, Wisconsin, took that passion to
another level. Because he understood helicopters
and how they fly (from his model-building
experience), moving to the Rotorway build
wasn’t scary. It was more of a challenge—a
challenge that he felt he was ready for based on
his start in model aviation.
You could say that model aviation was the
first step on his journey to full-scale flight; the
AMA led him to the EAA, and model flying
blossomed into full-scale flying.
The partnership between the AMA and the
EAA will no doubt transition more model
aircraft pilots into full-scale fliers and vice
versa, making this partnership a win-win for
everyone who loves general aviation and wants
to be involved. Whether it’s model or full-scale
flying, it’s the thrill of flying that counts!
Chuck’s dreams of building and flying his own
helicopter were realized on April 12, well ahead
of schedule. Since that time, he continues to enjoy
piloting his models and full-scale aircraft.
As I look at Chuck and Andrea’s new
adventure in aviation and the pride they feel
knowing that the dream of flight is no longer a
dream but a reality, I can’t help but notice that it
all started with a model—a flying model. MA
Sources:
Rotorway International
(480) 961-1001
www.rotorway.com
Left: Chuck poses
with the model
helicopters that
inspired him to
take on this fullscale
project.
Photos by the author
Edition: Model Aviation - 2011/12
Page Numbers: 38,39,40,41
Edition: Model Aviation - 2011/12
Page Numbers: 38,39,40,41
Top: The saying “measure twice and cut once” is useful no
matter the size of your project. In this case, it’s a full-scale
Rotorway Exec 162F helicopter.
Above: The Exec 162F is a two-seat helicopter, which is a
good thing since Chuck’s wife, Andrea, enjoys flying as well.
The heli has a maximum takeoff weight of 1,500 pounds and a
rotor diameter of 25 feet.
TRANSITIONING FROM flying model RC
helicopters to full-scale helis is no small feat, but
Chuck Bucci from Hales Corners, Wisconsin,
took on that challenge. Chuck bought a
Rotorway 162 F (kit helicopter) in October of
2010 and began building it in his garage. On January 21,
2011, only four short months later, the kit was 95% complete
and only hours of work away from its maiden flight.
After building and flying model helicopters, such as his
T-Rex 600, and after seeing a friend’s experimental
Rotorway Exec, Chuck decided that he wanted to build and
fly his own full-scale helicopter.
Right: The finished helicopter
in flight.
Clockwise from below: Various photos of the Rotorway during its
assembly in Chuck’s garage. His goal was to complete the project
in eight months.
December 2011 41
After many hours of research and networking
with others who have built Rotorway helicopters,
Chuck found a kit in Florida that had been
purchased from Rotorway but never built. The
owners of the kit didn’t have the time to build the
helicopter and decided to sell it.
An experienced local builder, who also
happened to own a Rotorway, offered his help and
the two set off for Florida to inspect the kit and
make sure that it was what Chuck wanted. The
asking price was within Chuck’s budget, but he
also had to consider the cost of the upgrades that
the helicopter would need.
After a careful inspection of the kit, the deal
was made and the Rotorway kit was on its way to
Wisconsin in a rented truck. Chuck’s transition into
full-scale experimental helicopters had begun.
This wasn’t a quick decision. Before Chuck
shelled out the money for the project, he did
something that many transition builders don’t do:
he took some lessons in a Rotorway. He took
lessons for eight hours, making sure that this was
what he wanted to do.
After flying the Rotorway 162F, he was ready to
go ahead with the project, but first things first! His
wife, Andrea, had to buy into the whole idea, too;
after all, this was a big commitment of time and
resources. Chuck wanted her to be a part of the
process, so Andrea took a ride in a Rotorway so she
could see where he wanted to go with his building
and flying. He wanted her to agree that this was a
good idea and that it would be a fun experience for
both of them. Andrea agreed and served as is his
copilot on the project and spent many hours
helping.
Chuck also visited the Rotorway factory in
Arizona to talk to the people with whom he would
be dealing during his build. He wanted to see where
the kits were made and what went into the
materials.
With his tour complete, Chuck felt confident
that the Rotorway was the best helicopter out there
for him as a first-time builder. Many like the idea
of building, but after they buy a kit and start the
work, the reality of the long hours and extra
resources needed hit home. Often, the kit doesn’t
get started because of lack of time and skills, and in
the end, it gets sold.
To ensure that wouldn’t be the case, Chuck
joined the Rotorway Owners Group and the EAA to
get the best advice. Members of both organizations
shared experiences and building techniques and
were helpful to Chuck during the build. A local
builder also assisted him with advice and checked to
make sure the build went as planned.
Building a full-scale helicopter such as the
Rotorway takes time, money, and a reasonable
amount of mechanical experience. Chuck has been
a self-employed electrical contractor for roughly 35
years. He has a basement full of metal-working
machine tools that he used to create parts for the
helicopter, saving him time and money and
eliminating the need for outside contractors.
Chuck had reasonable expectations of what it
would take to complete the build, plus the time and
cost to earn a pilot’s license. He and Andrea felt
that his timetable seemed realistic and acceptable,
and he wasn’t worried about losing interest in the
overwhelming work needed to complete the build
in the eight months he allotted.
Summer 2011 was set as the target completion
date. To Chuck, this wasn’t going to be a work in
progress, dragging on for years and years; it
would be an ongoing push every day until the
helicopter was complete.
When asked what he believed it would take to
do the build right and complete it in the eight
months he forecasted, he replied, “You have to
have the time and money to put into this;
otherwise you’re just fooling yourself.”
All right, we know the timeline was eight
months, but what about the cost?
Chuck believed he would invest $60,000 in the
helicopter, and that’s not counting the cost of
getting his pilot’s license. Considering what
helicopters sell for today, he believes that’s a low
price for a quality helicopter. Because he’s both
the builder and the mechanic, maintenance costs
would be lower compared to paying an A&P
aircraft mechanic to do the inspections and needed
repairs. Also, the cost per hour in fuel is a fraction
of that of a factory-built production helicopter.
All things considered, the Rotorway is a costefficient,
two-seat personal helicopter that is
affordable for the average builder.
At the age of 57, Chuck, who came to love
helicopters because of his six-year affiliation
with the Southeast Wisconsin Area Rotory
Modelers (SWARM) RC helicopter club in
Franklin, Wisconsin, took that passion to
another level. Because he understood helicopters
and how they fly (from his model-building
experience), moving to the Rotorway build
wasn’t scary. It was more of a challenge—a
challenge that he felt he was ready for based on
his start in model aviation.
You could say that model aviation was the
first step on his journey to full-scale flight; the
AMA led him to the EAA, and model flying
blossomed into full-scale flying.
The partnership between the AMA and the
EAA will no doubt transition more model
aircraft pilots into full-scale fliers and vice
versa, making this partnership a win-win for
everyone who loves general aviation and wants
to be involved. Whether it’s model or full-scale
flying, it’s the thrill of flying that counts!
Chuck’s dreams of building and flying his own
helicopter were realized on April 12, well ahead
of schedule. Since that time, he continues to enjoy
piloting his models and full-scale aircraft.
As I look at Chuck and Andrea’s new
adventure in aviation and the pride they feel
knowing that the dream of flight is no longer a
dream but a reality, I can’t help but notice that it
all started with a model—a flying model. MA
Sources:
Rotorway International
(480) 961-1001
www.rotorway.com
Left: Chuck poses
with the model
helicopters that
inspired him to
take on this fullscale
project.
Photos by the author
Edition: Model Aviation - 2011/12
Page Numbers: 38,39,40,41
Top: The saying “measure twice and cut once” is useful no
matter the size of your project. In this case, it’s a full-scale
Rotorway Exec 162F helicopter.
Above: The Exec 162F is a two-seat helicopter, which is a
good thing since Chuck’s wife, Andrea, enjoys flying as well.
The heli has a maximum takeoff weight of 1,500 pounds and a
rotor diameter of 25 feet.
TRANSITIONING FROM flying model RC
helicopters to full-scale helis is no small feat, but
Chuck Bucci from Hales Corners, Wisconsin,
took on that challenge. Chuck bought a
Rotorway 162 F (kit helicopter) in October of
2010 and began building it in his garage. On January 21,
2011, only four short months later, the kit was 95% complete
and only hours of work away from its maiden flight.
After building and flying model helicopters, such as his
T-Rex 600, and after seeing a friend’s experimental
Rotorway Exec, Chuck decided that he wanted to build and
fly his own full-scale helicopter.
Right: The finished helicopter
in flight.
Clockwise from below: Various photos of the Rotorway during its
assembly in Chuck’s garage. His goal was to complete the project
in eight months.
December 2011 41
After many hours of research and networking
with others who have built Rotorway helicopters,
Chuck found a kit in Florida that had been
purchased from Rotorway but never built. The
owners of the kit didn’t have the time to build the
helicopter and decided to sell it.
An experienced local builder, who also
happened to own a Rotorway, offered his help and
the two set off for Florida to inspect the kit and
make sure that it was what Chuck wanted. The
asking price was within Chuck’s budget, but he
also had to consider the cost of the upgrades that
the helicopter would need.
After a careful inspection of the kit, the deal
was made and the Rotorway kit was on its way to
Wisconsin in a rented truck. Chuck’s transition into
full-scale experimental helicopters had begun.
This wasn’t a quick decision. Before Chuck
shelled out the money for the project, he did
something that many transition builders don’t do:
he took some lessons in a Rotorway. He took
lessons for eight hours, making sure that this was
what he wanted to do.
After flying the Rotorway 162F, he was ready to
go ahead with the project, but first things first! His
wife, Andrea, had to buy into the whole idea, too;
after all, this was a big commitment of time and
resources. Chuck wanted her to be a part of the
process, so Andrea took a ride in a Rotorway so she
could see where he wanted to go with his building
and flying. He wanted her to agree that this was a
good idea and that it would be a fun experience for
both of them. Andrea agreed and served as is his
copilot on the project and spent many hours
helping.
Chuck also visited the Rotorway factory in
Arizona to talk to the people with whom he would
be dealing during his build. He wanted to see where
the kits were made and what went into the
materials.
With his tour complete, Chuck felt confident
that the Rotorway was the best helicopter out there
for him as a first-time builder. Many like the idea
of building, but after they buy a kit and start the
work, the reality of the long hours and extra
resources needed hit home. Often, the kit doesn’t
get started because of lack of time and skills, and in
the end, it gets sold.
To ensure that wouldn’t be the case, Chuck
joined the Rotorway Owners Group and the EAA to
get the best advice. Members of both organizations
shared experiences and building techniques and
were helpful to Chuck during the build. A local
builder also assisted him with advice and checked to
make sure the build went as planned.
Building a full-scale helicopter such as the
Rotorway takes time, money, and a reasonable
amount of mechanical experience. Chuck has been
a self-employed electrical contractor for roughly 35
years. He has a basement full of metal-working
machine tools that he used to create parts for the
helicopter, saving him time and money and
eliminating the need for outside contractors.
Chuck had reasonable expectations of what it
would take to complete the build, plus the time and
cost to earn a pilot’s license. He and Andrea felt
that his timetable seemed realistic and acceptable,
and he wasn’t worried about losing interest in the
overwhelming work needed to complete the build
in the eight months he allotted.
Summer 2011 was set as the target completion
date. To Chuck, this wasn’t going to be a work in
progress, dragging on for years and years; it
would be an ongoing push every day until the
helicopter was complete.
When asked what he believed it would take to
do the build right and complete it in the eight
months he forecasted, he replied, “You have to
have the time and money to put into this;
otherwise you’re just fooling yourself.”
All right, we know the timeline was eight
months, but what about the cost?
Chuck believed he would invest $60,000 in the
helicopter, and that’s not counting the cost of
getting his pilot’s license. Considering what
helicopters sell for today, he believes that’s a low
price for a quality helicopter. Because he’s both
the builder and the mechanic, maintenance costs
would be lower compared to paying an A&P
aircraft mechanic to do the inspections and needed
repairs. Also, the cost per hour in fuel is a fraction
of that of a factory-built production helicopter.
All things considered, the Rotorway is a costefficient,
two-seat personal helicopter that is
affordable for the average builder.
At the age of 57, Chuck, who came to love
helicopters because of his six-year affiliation
with the Southeast Wisconsin Area Rotory
Modelers (SWARM) RC helicopter club in
Franklin, Wisconsin, took that passion to
another level. Because he understood helicopters
and how they fly (from his model-building
experience), moving to the Rotorway build
wasn’t scary. It was more of a challenge—a
challenge that he felt he was ready for based on
his start in model aviation.
You could say that model aviation was the
first step on his journey to full-scale flight; the
AMA led him to the EAA, and model flying
blossomed into full-scale flying.
The partnership between the AMA and the
EAA will no doubt transition more model
aircraft pilots into full-scale fliers and vice
versa, making this partnership a win-win for
everyone who loves general aviation and wants
to be involved. Whether it’s model or full-scale
flying, it’s the thrill of flying that counts!
Chuck’s dreams of building and flying his own
helicopter were realized on April 12, well ahead
of schedule. Since that time, he continues to enjoy
piloting his models and full-scale aircraft.
As I look at Chuck and Andrea’s new
adventure in aviation and the pride they feel
knowing that the dream of flight is no longer a
dream but a reality, I can’t help but notice that it
all started with a model—a flying model. MA
Sources:
Rotorway International
(480) 961-1001
www.rotorway.com
Left: Chuck poses
with the model
helicopters that
inspired him to
take on this fullscale
project.
Photos by the author
Edition: Model Aviation - 2011/12
Page Numbers: 38,39,40,41
Top: The saying “measure twice and cut once” is useful no
matter the size of your project. In this case, it’s a full-scale
Rotorway Exec 162F helicopter.
Above: The Exec 162F is a two-seat helicopter, which is a
good thing since Chuck’s wife, Andrea, enjoys flying as well.
The heli has a maximum takeoff weight of 1,500 pounds and a
rotor diameter of 25 feet.
TRANSITIONING FROM flying model RC
helicopters to full-scale helis is no small feat, but
Chuck Bucci from Hales Corners, Wisconsin,
took on that challenge. Chuck bought a
Rotorway 162 F (kit helicopter) in October of
2010 and began building it in his garage. On January 21,
2011, only four short months later, the kit was 95% complete
and only hours of work away from its maiden flight.
After building and flying model helicopters, such as his
T-Rex 600, and after seeing a friend’s experimental
Rotorway Exec, Chuck decided that he wanted to build and
fly his own full-scale helicopter.
Right: The finished helicopter
in flight.
Clockwise from below: Various photos of the Rotorway during its
assembly in Chuck’s garage. His goal was to complete the project
in eight months.
December 2011 41
After many hours of research and networking
with others who have built Rotorway helicopters,
Chuck found a kit in Florida that had been
purchased from Rotorway but never built. The
owners of the kit didn’t have the time to build the
helicopter and decided to sell it.
An experienced local builder, who also
happened to own a Rotorway, offered his help and
the two set off for Florida to inspect the kit and
make sure that it was what Chuck wanted. The
asking price was within Chuck’s budget, but he
also had to consider the cost of the upgrades that
the helicopter would need.
After a careful inspection of the kit, the deal
was made and the Rotorway kit was on its way to
Wisconsin in a rented truck. Chuck’s transition into
full-scale experimental helicopters had begun.
This wasn’t a quick decision. Before Chuck
shelled out the money for the project, he did
something that many transition builders don’t do:
he took some lessons in a Rotorway. He took
lessons for eight hours, making sure that this was
what he wanted to do.
After flying the Rotorway 162F, he was ready to
go ahead with the project, but first things first! His
wife, Andrea, had to buy into the whole idea, too;
after all, this was a big commitment of time and
resources. Chuck wanted her to be a part of the
process, so Andrea took a ride in a Rotorway so she
could see where he wanted to go with his building
and flying. He wanted her to agree that this was a
good idea and that it would be a fun experience for
both of them. Andrea agreed and served as is his
copilot on the project and spent many hours
helping.
Chuck also visited the Rotorway factory in
Arizona to talk to the people with whom he would
be dealing during his build. He wanted to see where
the kits were made and what went into the
materials.
With his tour complete, Chuck felt confident
that the Rotorway was the best helicopter out there
for him as a first-time builder. Many like the idea
of building, but after they buy a kit and start the
work, the reality of the long hours and extra
resources needed hit home. Often, the kit doesn’t
get started because of lack of time and skills, and in
the end, it gets sold.
To ensure that wouldn’t be the case, Chuck
joined the Rotorway Owners Group and the EAA to
get the best advice. Members of both organizations
shared experiences and building techniques and
were helpful to Chuck during the build. A local
builder also assisted him with advice and checked to
make sure the build went as planned.
Building a full-scale helicopter such as the
Rotorway takes time, money, and a reasonable
amount of mechanical experience. Chuck has been
a self-employed electrical contractor for roughly 35
years. He has a basement full of metal-working
machine tools that he used to create parts for the
helicopter, saving him time and money and
eliminating the need for outside contractors.
Chuck had reasonable expectations of what it
would take to complete the build, plus the time and
cost to earn a pilot’s license. He and Andrea felt
that his timetable seemed realistic and acceptable,
and he wasn’t worried about losing interest in the
overwhelming work needed to complete the build
in the eight months he allotted.
Summer 2011 was set as the target completion
date. To Chuck, this wasn’t going to be a work in
progress, dragging on for years and years; it
would be an ongoing push every day until the
helicopter was complete.
When asked what he believed it would take to
do the build right and complete it in the eight
months he forecasted, he replied, “You have to
have the time and money to put into this;
otherwise you’re just fooling yourself.”
All right, we know the timeline was eight
months, but what about the cost?
Chuck believed he would invest $60,000 in the
helicopter, and that’s not counting the cost of
getting his pilot’s license. Considering what
helicopters sell for today, he believes that’s a low
price for a quality helicopter. Because he’s both
the builder and the mechanic, maintenance costs
would be lower compared to paying an A&P
aircraft mechanic to do the inspections and needed
repairs. Also, the cost per hour in fuel is a fraction
of that of a factory-built production helicopter.
All things considered, the Rotorway is a costefficient,
two-seat personal helicopter that is
affordable for the average builder.
At the age of 57, Chuck, who came to love
helicopters because of his six-year affiliation
with the Southeast Wisconsin Area Rotory
Modelers (SWARM) RC helicopter club in
Franklin, Wisconsin, took that passion to
another level. Because he understood helicopters
and how they fly (from his model-building
experience), moving to the Rotorway build
wasn’t scary. It was more of a challenge—a
challenge that he felt he was ready for based on
his start in model aviation.
You could say that model aviation was the
first step on his journey to full-scale flight; the
AMA led him to the EAA, and model flying
blossomed into full-scale flying.
The partnership between the AMA and the
EAA will no doubt transition more model
aircraft pilots into full-scale fliers and vice
versa, making this partnership a win-win for
everyone who loves general aviation and wants
to be involved. Whether it’s model or full-scale
flying, it’s the thrill of flying that counts!
Chuck’s dreams of building and flying his own
helicopter were realized on April 12, well ahead
of schedule. Since that time, he continues to enjoy
piloting his models and full-scale aircraft.
As I look at Chuck and Andrea’s new
adventure in aviation and the pride they feel
knowing that the dream of flight is no longer a
dream but a reality, I can’t help but notice that it
all started with a model—a flying model. MA
Sources:
Rotorway International
(480) 961-1001
www.rotorway.com
Left: Chuck poses
with the model
helicopters that
inspired him to
take on this fullscale
project.
Photos by the author
