INSTRUCTION MANUAL

5/74 e?fP

MANUAL 5

COPYRIGHT, 1974. PALMER AEROSYSTEMS

I"" PALMER AEROSYSTEMS

ACV-I-8

The ACV-1-8 air cushion vehicle is designed to provide a very low cost touring and training vehicle that is easy to maintain and operate. Design emphasis was placed on high reliability through simplicity, conservatively designed drive and rotors, and the use of a mildly tuned powerpl ant ,

The vehicle can be built for approximately $350, and can be dismantled and placed on top of an auto by one person, eliminating the expense and bother associated with a trailer.

Standard vertical shaft 4 cycle lawnmawer engines can be used on the vehicle.

An engine of 5 to 8 horsepower should be used, and if an engine is purchased for the craft, it is recommended that 8 horsepower be used to achieve good part throttle operation.

The prototype is equipped with an 8 horsepower engine, and with this engine, is capable of planing out from a s top a 250 pound payload and acceler ating it to

19 miles per hour while pulling a modest 6.4 horsepower at 3200 rpm. Performance is higher in salt water, tailwinds, and cold weather, while high altitudes, headwinds and hot weather may reduce performance. The craft uses about .7 gallons per hour (27 mpg) while cruising on water.

The noise level of the craft is dependent upon engine muffling as the rotors are relatively quiet. The prototype noise level is 83 dB (A) at 50 feet at cruise.

This manual should be regarded as an integral part of the plans for the vehicle, and it should be read and understood, along with the 4 sheets of drawings, before construction is initiated.

As the seller of these plans has no control over the workmanship of the product produced from these plans, the buyer must assume all responsibility for liability and warrantee of said product, and the purchase of these plans constitutes a nonexclusive right to the fabrication and use of one of these vehicles by the buyer. The buyer should be advised that if poor workmanship i.s h the rotating oompo aent s

of the prod uct, not only will it be unreliable, bet the rotating assemblies themselves may constitute a real danger to the operator of the product and to bystanders if the operational safety precautions as outlined later in this manual are not observed.

PREPARATION FOR CONSTRUCTION

A ventilated space should be selected for a shop area as polyester and epoxy resins, along with paints and solvents are to be used in fabrication of the vehicle.

A saber saw and a 1/4 inch hand power drill are the only power tools required for the construction proces s. Special tools required are a set of hole saws for the drill, and a solid oxygen-propane torch ($25-$40) which can be purchased at a well stocked hardware store.

Materials are easy to obtain. All woad parts are cut from stock lumber yard

1

sections. The balsa and aircraft plywood can be purchased from a hobby shop and the 1/8 plywood deck skin is inexpensive" Lauan" doors kin material. The '-- urethane foam used in the design can be purchased from a plastics shop or insulation specialty house. The polystyrene flotation logs are stock dock floats.

The following instructions are arranged to describe construction on a drawing '-' by drawing basis. Construction can be speeded greatly if all materials are ordered immediately, and fabrication of as many parts as practical be undertaken

at one time.

HULL, RUDDER, FLOATS (SHEET 1)

Hull construction is started by jol n inq 1/8 plywood panels together to form the deck skin. A 2 in. wide strip of plywood is epoxied to what will become the underside of the deck to form a joint. JOints should be located so that a minimum

of notching of the frames and stringers will be required when the skin is attached.

The toe box should then be assembled from 1/8 in ply. The assembly should

be nailed together with 5/8 in brass ringnails after the joints are coated with epoxy. At this time, the two 5/16 in. by 1 5/8 in lattice sections should be glued together to form stock for the 5 frames. The frames are then match cut.

The stringers should then be as sembled to the toe box along with the frames.

The 1/8 plywood web in the stringer need not be a continuous section.

The two 5/16 in. by 3/4 in. stringers should then be installed in notches in the frames. The hull structure should then be notched to take the deck skin joints and the skin should then be glued in place.

After the deck skin is in place, the ends of the stringers and frames should be accurately trimmed, and the 3/4 in. square hull peripheral structure is then cemented in place. The stock should be bevelled to fit the deck skin.

The .smal l triangular gussetts are then put in place and the lower portion of the toe box glassed with 6 oz "boat" glass to complete the hull woodwork.

"-" The styrofoam floats are then cut to size, using an ordinary handsaw to cut away

large sections and a kitchen knife to cut fine details. The lower sections of the floats should be cut after the floats are attached to the hull.

The wood parts of the hull can now be painted except in the areas where the floats are to be bonded to the structure. The floats are then notched to fit the hull frames and the outboard sides of the stringers. Liberal amounts of epoxy should then be used '-' to bond the floats in place.

The float bottoms are then cut to shape using the hull periphery as a guide. At this time, the electrical conduit that retains the lower forward edge of the aft skirt must

2

be put in place. (See sheet 4). The holes that take the conduit may be bored by heating a piece of conduit over a stove and pres sing it into the float at the proper

angle. ~

The rudder and rudder components are then fabricated, and 2 in. thick urethane insulating foam is bonded in place. The foam is then s anded down using a coarse grade of sandpaper. The airfoil shape is not critical.

A coating of 6 02. "boat" glass is then applied using polyester laminating resin, which will "dry" to a tacky surface. The rudder is then trimmed and the glassed portions are given a sealing coat of pigmented polyester surfacing resin. (Note:

If, after the rudder is glas sed, it dries to a hard, dry, waxy surface, finishing resin was mistakenly used in place of laminating resin, and the waxy surface must be sanded off before additional c oats of resin can be applied. This goes for all glassed surfaces, except for the underside of the toe box, which can be glassed using finishing resin only.)

If a more rugged vehicle is desired, it is advisable to use 1/4 in. plywood in the seat area and in the floor of the toe box. An extremely light weight hull can be skinned with glider fabric, as is the prototype. Under no circumstances should the entire deck be skinned with 1/4 in. ply.

ROTORS (SHEET 2)

Although the idea of building the rotors for the craft may at first horrify the average craftsman, it is really not difficult at all. It is advisable, however, to build a miniature of the propeller before undertaking the full scale job. Not only does such a project develop the necessary skills for building the rotors, but may save the builder from ruining an expensive piece of balsa.

The lift fan can be made from two lengths of 1 1/2 in. by 3 in. by 36 in. balsa blocks along with some scraps to form the thick hub region. The propeller may have to be made up from a glued up balsa blank. When gluing up a blank, location of the joints does not matter, as the glass covering will ultimately take the structural loads. However, to simplify balancing of the rotors, joints in one blade should be similarly positioned in the other blade.

The first step in carving the propeller is to cut the profile of the blades (shape

of the rotor when looking along the line of thrust). The leading and trailing edge lines

are drawn first. The blank is then clamped with its face against a bench and

material is removed using a draw knife or wood rasp to yield the four sided" airfoil" as shown in the lower right corner of sheet 2 and in the end view of the propeller blank. Additional material is removed to eventually yield the cambered airfoil as

shown in the lower right corner of sheet 2. Carving should be kept orderly, and ~

the blades should be free of wav me s s after each step in the generation of the blade

airfoil. Care should be taken to not excessively dull the blade leading edges.

After the airfoil has been generated, the propeller tips are then rounded ~"

3

into the flat blade surface, and the leading and trailing edge tip corners are slightly radiused. The aircraft plywood hub reinforcements are then chamfered to blend into ~ the propeller hub surfaces and are cemented in place. (The outline of these pieces as shown on the drawing is meant to represent a starting shape, and only that portion of the hub within a 2 in. radius of the propeller axis need be flat.)

The lift fan blades are carved from stock before the fan is bonded together, as it is difficult to carve a blade with other blades in the way. (It helps to complete carving a blade before cutting it away from the parent stock so that it. is easier to clamp to a workbench for carving.) The fan blade tips are left squared off.

After the fan and propeller blanks are carved, they should be checked for balance, track, and pitch. This preliminary procedure will prevent problems which may occur later.

~ The rotor center hole is drilled and the propeller shaft inserted so that it projects

beyond both sides of the hub. The shaft is then placed on two horizontal, parallel straightedges with the rotor free to pivot between them. Sma l l wooden wedges are then forced between the shaft and center hole so that the shaft is positioned so that the rotor blades follow each other when the rotor is allowed to turn. In the case of the propeller, if the hub is tilted about an axis through the blades, one blade can

be inadvertently given a greater pitch then the other , and the shaft should be adjusted to eliminate this condit ion . If the fa2: :5 properly tracked, blade pitch will automatically be established. The rotors are the2: placed with the shaft vertical, and the

gap between the shaft and center hole taped so that polyester resin can be poured

into the gap to fix the s haft in position.

~

The small wedges are then removed after the polyester resin sets, and the shaft is removed from the rotor. (A sharp blow may be required. It helps to wax the shaft prior to fixing it in the rotor.)

The rotor then should be checked for balance by inserting the shaft and pl ac inq

the assembly on the straightedges. The heavy blade will settle. A bolt or nut or other object is then taped to the rotor near the hub until the rotor balances. A cavity

is cut in the rotor at the point to which the balance weight was taped and the balance weight is cemented into the hole with epoxy. Sometimes a small amount of balsa can be removed to achieve balance. Any weight should be kept within 6 inches of the pro-

'-" peller axis, and within 3 inches of the fan axis.

The rotors are now ready to be glassed. A small batch of polyester putty, polyester laminating resin and a single piece of 6 oz. "boat" cloth is prepared to apply to a complete rotor surface. The laminating resin should be pigmented with 1/2 of the normal quantity of pigment (different pigments vary in concentration) and the glass cut so that it overhangs the blade edges by 1/4 - i/2 inch and there is sufficient glass to wrap

.....,. more than half way around the hub sides. The putty and white pigmented laminating

resin are then catalysed and the glass is wetted out on the rotor using the putty to hold down stubborn edges. The resin should be applied sparingly so that the glass does not float off the balsa surfaces. During the wetting out process the glass at the blade edges

~. should be trimmed to 1/8 -3/16 inch from the balsa edges.

4

The rotor is then turned over and the proces s repeated, making sure that the lead-

ing and trailing edges are well filled with putty so that there will be no bubbles ~"

between the layers of glass where they extend beyond the balsa.

After the resin cures to a tacky surface, the rotor is then cleaned up and the glass that overhangs the blade edges is trimmed to 1/8 inch from the balsa using a block and sandpaper to yield a true edge which is relatively free of waviness.

The next step is to give the rotor leading edges a second covering of glas s , which wraps around the leading edges. Mix some laminating resin, as before, and layout

a strip of glas s 2 1/4 inches wide on a smooth piece of aluminum foil. Wet out the blade leading edge and at the same time wet out the glass strip on the aluminum forl , Place

the glass over the leading edge and wrap the aluminum foil around the surface to hold ~

the glass in place. Try to avoid wrinkling the aluminum foil in this operation so resin

won I t run out of a wrinkle. The propeller leading edges may be put on in three pieces

to minimise wrinkles in the foil.

The aluminum foil is removed after the resin has cured. The rotor is then cleaned of projecting glas s and resin, bubbles are filled and the glass which is over the center hole is removed. The rotor is then painted with polyester resin which is pigmented

at full concentration. The resin should be of the finishing type so that it will cure to a hard, tack free surface. This surface is then sanded smooth. The entire surface should be scratched with sandpaper, and the painting process repeated as before, ex-

cept that the shaft should be in position at this time. ~<

The rotor is now ready for final balance, track, and pitch. The same procedure as outlined previously is followed. A weight, which is likely to be very small when compared to the initial balance weight, is taped to the rotor as before until balance is achieved and a hole is drilled in the hub at the point where balance was achieved and the weight is cemented in as before.

Track and pitch should check out as initially set. The blades should track, or follow each other within 1/8 inch, and the rotor blade pitch should be consistent within 1/8 inch as determined by comparing leading and trailing edge tracking.

Balance is checked as follows. The horizontal straightedges are elevated at one end so as to make them slope 1/32 inch per I foot run. The rotor and shaft assembly should be able to start up and roll down the slope after being placed in any angular position on the parallels. An off balance rotor will tend to limp down the parallels, or stop altogether when it is placed in some angular positions.

The shaft is used as a guide when the sheaves are installed on the rotors.

The four 1/4 inch holes are drilled through the rotors using the respective sheave as a guide. The 1/4 aircraft ply propeller spacers are also drilled at this time.

The rotors are as sembled to their sheaves using the propeller shaft as a guide

5

and are given a final check for balance, track, and pitch. The blade tips should be painted a bright color to complete the fabrication proce s s .

FRAME, FAN SHROUD, AIR DRIVE UNIT, GUARD (SHEET 3)

The wood parts of the air drive unit should be fabricated first, keeping in mind that some of the holes may be difficult to drill after fabrication is under way. A hole saw can be used to drill out the wood to take the four pieces of conduit which support

the propeller bearings.

The four conduit supports are match. drilled to the wood parts, and are installed in the wood parts by bolting and potting the clearance between metal and wood with epoxy. The propeller bearings should be installed at this time, as the two bolts which hold the upper ends of the conduit also hold the bearing flanges in place.

The engine, Corvair idlers, propeller, fan and vee belt are- installed at this time along with the belt tensioner for a trial fit.

After the builder is certain that everything fits, the urethane foam which forms the fan shroud may be cut from 2 in. i n s ul at io n stock and cemented in place. (Another melhod of forming the foam i.s to bui Id cardboard dams around the plywood base of the fan shroud and use foam in place urethane foam.)

The foam is then sanded to shape with the inner radius shaped using the shaft of ~ the installed engine as a guide to insure precision of the fan tip clearance.

The foam and propeller bearing cover are then glassed as described previously and the rotor stand is ready for a finish.

The wire screen is installed by drilling 1/16 in holes at locations which line up with a piece of the mesh when it is placed over the particular space where it is to

be installed, and cutting the mesh to size and cementing it into the holes with epoxy. The wire should penetrate into the shroud or engine mount at least 3/4 inch.

The fan is then checked for tip clearance. If the blades are too close to the shroud, a piece of sandpaper is taped to the shroud with a cardboard spacer, and the fan, which is on the engine shaft, is rocked past the sandpaper. The sandpaper should be placed on the shroud where fan to shroud clearance is least.

The air drive unit is as sembled and all threaded fasteners are safetied by painting exposed threads with contact cement. The belt is tensioned to a reasonable taughtness. If a 1 pound force is applied to the belt midway between an idler and the propeller pulley I and the belt moves 1/8 inch, the belt is correctly tightened. (A 1 pound postal scale can be used for this process.)

The guard is brazed together using a solid oxygen-propane brazing torch. mesh is cut as it is brazed to the finished guard frame.

The wire

The stick, rudder, a throttle and ignition short switch are installed on the air drive. 6

The guard and stick are fitted and match drilled to the rudder shuttle and air drive unit. A coat of rust inhibiting enamel and finish coat are applied to the metal parts (except bore s, drilled holes and vee belt flanges and idlers) to. complete work outlined on sheet 3. (Note that the idler installation is diagrammed on sheet 4.)

\

SKIR T (SHEET 4)

It is advisable to as semble a paper scale model of the skirt to learn its configuration before undertaking the full sized skirt. The four main skirt segments are cut out and glued together with vinyl pipe fitting cement first. The segments are assembled inside out t by glueing the wide flap (de tai l , upper right corner of sheet 4). The forward quarter skirts are then attached and the assembly is turned right side out so that the 1 in. wide scaler strips can be bonded in place. Like any large fabric structure t the skirt

is difficult to position to make accurate joints t and a little patience may be required. The joints should be placed under light compression while they are cur inq t but due to

the shapes involved it may be possible to tape the joint and .after cure t go back and

fill in bad spots in the joi nt ,

The skirt lower edges are then bonded to the 5/16 in. by 1 5/8 in. lattice strips

that will ultimately fit into the qroov e s which are cut into the bottom of the floats.

The next step is to bond the skirt to the lower edge of the hull periphery, and cement the small strip shown in the sectional view in the lower right corner of sheet 4 to the outer surface of the hull periphery and the skirt. 1/4 inch ply reinforcements are then

nailed to the underside of the hull periphery at the rear, rear corners t and at the forward ~/ apexes of the forward quarter skirts to reinforce these critical areas.

The bow skirt is then drawn on the skirt material, and it is cut out leaving a margin of two inches around the edges. The inner edges of the rear and side skirts are then inserted into the groove in the floats, and pinned in place with aluminum rain gutter nails, which are slipped through pre-drilled holes in the lattice (two nails per each of 6 pieces of lattice.) The bow skirt is then positioned with tape and pins with the skirt forward quarters positioned as close as practical to their inflated position. If the bow skirt appears to "drape" correctly it can be given a final trim and permanently bonded

to the outer surface of the hull peripheral structure and to the quarter skirts along a line marked" 0" on the quarter skirt drawing. Otherwise t it must be adjusted and cut accord- ~' ing to the new position.

Details, such as view" G" and the skirt drain and reinforcements can be fabricated when convenient. The forward edge of the rear skirt flap can be glued to the conduit to facilitate construction of the skirt in view" G" .

A n aluminum countertop trim strip is attached around the vehicle periphery to give the assembly a finished look.

7

VEHICLE SETUP, CHECKOUT, AND OPERATION

The entire vehicle can be carried atop an auto if the hull is carried on top and the air drive is fitted to a brac ke.t which hooks to the upper edge of a trunk lid.

If high travelling speeds are anticipated, the craft should be hauled on a trailer.

To set up the vehicle, the hull is placed on the ground and the air drive unit

is hooked in place. (With practice, this can be a one man operation, provided the guard is removed and reinstalled during setup.)

"J.JtI

The spark plug lead is installed (it should always be disconnected when the vehicle is not in use or is being serviced) gas and oil checked and fuel tank valve turned on. The throttle lever is then placed in the start-choke position and the ignition short switch is opened. The engine should be checked to make sure that the choke has cycled to a closed position. The engine is then started, using the recoil start rope only, and the ignition short switch is immediately thrown to check it out. If the engine does not stop firing immediately it will eventually stop due to the choked condition. If the engine does not stop crisply when the short s witch is thrown, the switch is not working, and should be made operable before any attempt is made to operate the engine in an unchoked condition.

After the ignition short switch function is verified, the engine is started and the throttle is moved to the idle position. Advancing the throttle to the stop position momentarily will check out a second ignition short device if the engine misses.

With the engine at idle, vibration should be observed. Some vibration due to the engine and belt whip will be observed. If the vibration appears to be beyond that of a lawn mower, or some surfaces seem to sting when touched, the vibration may be too severe and rotor balance should be checked.

After the unit passes its idle vibration tests, the throttle is slowly advanced and vibration is observed, along with the fact that the vehicle has lifted off and is underway. The belt will go through whip at some speeds and this should be of

no concern. (The vehicle should never be operated without the guard as not only is it essential for safety, but figures in suppression of air drive unit vibration.)

~ After the vehicle functional checkout is completed, it is time to learn how to

operate it. The following safety rules should be observed.

Never place anything on the craft that might be ingested into the rotors. If it

is remotely conceivably possible for an item such as a scarf or tool to pass through a rotor, it will eventually find a way to go through. All bolts, including the two that hold the guard to the rotor stand should be safetied.

Never operate the vehicle at full rpm near bystanders. The vehicle attracts a crowd quite rapidly, and bystanders don't generally understand its operation. Also, although it is highly unlikely with the mildly stressed rotors used in this

\~ design, if a rotor should lose a blade, it will do it at full speed, and never at part throttle, provided that full speed operation had been reached previously.

8

The vehicle should never be pushed if it becomes stuck. The safest way to disloge a stuck vehicle is to pull it. The static thrust of some 4) pounds produced

by the craft is easily restrained by one person. ~

Operation of the vehicle can be learned instinctively in a few minutes. Improvement in driver technique will continue for some 500 plus hours.

To steer the vehicle, the stick is forced forwards and backwards by rotating one's upper body and arms in the direction of the desired turn. Full rudder travel should be used at slow speeds, and power should be applied during rudder operation.

Power changes should be made very gradually until the operator gains a reasonable amount of control, and it is rarely good practice to make rapid power changes.

The operator should lean away from a sideslip, and power should not be reduced when the vehicle is sideslipping. The vehicle should never be backslid at any significant speed. The vehicle should be trimmed fore and aft by shifting the seat position.

It should be appreciated that the vehicle is very fast, in spite of the seemingly modest claims of speed, and things can get out of hand--very rapidly, if the operator does not plan ahead. If the operator does get in trouble, he should straighten it out and hit the ignition short switch. The stop will be very rapid! !

Safe operation is 99% common sense. If the operator takes the time to learn how

to properly operate the vehicle, not only will he have an unusual vehicle, but a versatile vehicle, capable of operating in places no other vehicle can enter. The prototype has been driven up winding, rapid rivers and, although it is a bit small to be considered a "big water" boat, has made ope n water crossings as long as 5 miles.

A properly built vehicle is extremely reliable, as a mildly tuned engine is used instead of the usual cantankerous snowmobile engine as is found on almost aU commercial vehicles. The craft is the first of a new breed of air cushion vehicles, in which good performance is obtained on. a reasonable amount of power.

BILL OF MATERIALS

Quantity

Item Use

5 3 5 12 1 1 1 2 1

1/8"x3'x7' "Lauan" doorskin Hull

3/4 "x3/4 "x12' c 'fir, pine "

1/2 "x3/4"x12, c'fir, pine "

5/l6"xl 5/8"x7' lattice "

5/16"xl 5/8"xlO' lattice "

3/4"x3/4"xlO' Miter Stock "

l/4"xl'x4' Aircraft Plywood Hull, Air Drive Unit, Propeller,Fan

10"x20"xlO' Polystyrene Dock Floats Hull

3/4"x14" Thi nwal l Elec. Conduit Rudder

Air Conditioner Duct tape

Rudder

9

Quantity

Item

II II

7' Auto Weatherstrip "

Pt. PVC Pipefitting Ce me n; Skirt

Pt. Contact Cement Bol t Safety, Air Drive

Qt. Epoxy Cement Wood Parts

6 oz. Fiberglass, Approx. 38"x4Yd. Hull, Rudder, Air Drive Propeller, Fan

Gallon, Polyester Resin, Pigment " " "" " "

2" Urethane insulating Foam 24 Rudder, Air Drive

1" Eyebolt Sq. Ft. Air Drive

~~

7 1 3

~l

1 1 1 1 2 1

~ 1 1 2 1

2x4x5' stock fir 2x2x4' stock fir

1/2 "x 10' Thinwall Elec. Conduit 60"x8' 1"x2" Me sh Wire Fence

1 1/2 "x3 "x36" Balsa

2 "x6"x48" Balsa, or build up size pin 830 Engine, 8 hp , Vert. Shaft pin 831 Shaft, Steel. 1" Dia.

pin 832 Sheave, 3/8" ,8"P. D. pin 833 Vee Belt 3V950

pin 834 Bearing, Flanges, 1 "bore pin 835 Tapered Bushing, l"bore pin 836 1/4"x1/4"xl" Key

pin 837 C. I. Sheave 3/8"x 3.60" Corvair Idler

60" Width, x 15 Yd. 10 oz. Nylon

Reinforced Vynyl 1" Pipe as req'd

Throttle Assy, Lawnmower Switch, Ignition Short

1 1 1 1 1 1

~ 1 1 1 1 1

Use

Air Drive

Air Drive, Guard, Stick, Hull Guard, Air Drive

Fan

Propeller

Air Drive

II 'I

II II

II 11

II "

Fan

Engine Shaft Fan

Air Drive

Skirt

Engine :ihaft Air Drive

II II

"

1/4" Bolt, Nut, 2 Washers Quantity/Size,

5/1 1/4", 2/1 3 4", 4/2", 4/4 1/2" ,8 5 1 2"

5/16" Bolt, Nut, 2 \Vashers Quantity/Size,

1/3" ,2/3 1/2", 2 4 1 2", 2 7"

Misc.

4/3/8"x3 1/2" Bolt, Nut, 2 Washers, 1/7/16" Washer, 5/8" or 3/4" Bronze Ringnails 12/ Aluminum Rain Gutter Nail

NOTES:

It is not necessary to bolt the forward section of the air drive unit to the hull if the machine is to be used for normal touring. If rallying or other violent maneuvering is anticipated, the air drive should be bolted down .

. ~

Two of these vehicles can be built for much les s than the price of any two place vehicle. Be extremely wary about planning ahead if another vehicle is present.

Buy only Palmer Aerosystems approved components for your vehicle. As demand for parts increases, items other than the numbered parts will become available.

10

NOTES, Cont'd

At slow speeds, in tight quarters, it may be impractical to apply power for

rudder control. To turn, lean back and toward the des ired direction so that air ~,

from the cushion forces the bow to the side.

Try to keep water out of the lift fan. Don't operate in water which is so rough that spray strikes the fan.

Don't expect too much performance from this craft in heavy grass, as the very low cushion pressure used in the design will not mash down grass for an effective seal. The relatively low cushion pressure-does allow spray free operation over water, short grass, rocky river beds,sand, marsh, mudflats, snowfields and other surfaces.

The machine is not designed to be indiscriminantly rammed into boat wakes or seas. The hull structure is light to save weight. Be careful when sitting down or walking on the toe box floor.

If the vehicle starts to porpoise over periodic waves, or if the bow begins to drop,lean back and slow down.

When getting onto cushion after a period of floating in water, run the craft at low power, on cushion, for a short while before attempting to plane out. This allows time for water to be purged from the skirt.

Build the propeller from the dimensions shown in brackets, as they reflect the latest design. The wide bladed propeller as drawn is superior only if land operations only are contemplated. The narrow blade propeller will give a better

cruise speed. ~

Above all, if it is desired to experiment, BUILD THE CRAFT AS IT APPEARS IN THE PLANS, FIRST, and then modify the design.

11

CAREFUL ROTOR BALANCING IS THE KEY TO RELIABLE VEHICLE OPERATION. THE BALANCE ARBOR SHOULD ROLL ON HARD, SMOOTH SURFACES SUCH AS THE TOPS OF THE TWO LEVELS, AS SHOWN.

RO,O~5 fo,Rt.

Cfo,R~[D l~ fOUR Sfo,SlC

SIt.?S.

AIR DRIVE UNIT, LOOKING AFT.

13

PROTOTYPE HULL STRUCTURE. NOTE MINOR VARIATIONS FROM THE PLANS

TWO MAY RIDE IN TANDEM IF THE TOTAL WEIGHT IS NOT IN EXCESS OF 250 POUNDS. 14

... a

20S"0-S"S"2 (902) SSOB6 'VM 'NOIN3M 'l69 xoa 'O'd SW31SASOM3V M3W1Vd

FAN· TASTIC barely ripples the water as it skims quietly along at over 20 mph on an incredibly low six horsepower! This unique craft, which is powered with an ordinary, mild mannered garden tractor engine

for outstanding reliability, and which anyone can build with simple tools for around $350 will carry an adult and youngster of up ~250 pounds combined weight over field, marsh, beach, snow, up rapid rivers and into hard to reach places where the great outdoors is at its greatest. For the fun of flying, on a seven inch thick cushion

of air, its FAN -TASTIC

~you want to know more about these amazing vehicles? IIPractical Design Guide for Airboats and Air Cushion Vehiclesll is written so that the average person can design hulls, skirts, propellers, fans, engine and drive installations and build an airboat or air cushion v-"'icle that gets outstanding performance on modest ~er.

TQ~ 92 page book is packed with pictures of vehicles, ~grams, and worked out design examples.

Price: $6.50 Incl. First Class Postage

"-' Try the

F AN- TASTI C new sport of surface skimming

MANUFACTURERS: Are you singing the high horsepower, low performance blues? Try Palmer Aerosystems for innovative consultation, from the theoretical to the practical.

15 HP. SURFACE SKIMMER, FOR THE EXPERIMENTER

This vehicle is designed for the experimenter, and a variety of engines may be fitted, from 2 3-1/2 hp. mower engines to kart engines, to a single 15 hp. snowmobile engine. Payload is 250

to 400 pounds, depending on installed power.

Various methods of construction are detailed and this planset is an ideal complement to the Practical Design Guide. Construction and operation of the vehicle is completely detailed in 5 large construction drawings and an instruction manual, which contains pictures of the operating vehicle and construction details.

Price: $6.50 Incl. First Class Postage

15 HP. AIRBOAT, FOR THE OUTDOORSMAN

A product of aerospace engineering, this airboat was developed in the Florida Everglades

so that you may run duck loaded marshes and find hidden lunker bass holes in areas which are simply unreachable by other outdoorsmen.

Boat payload is 250 pounds, and a huge enclosed ~ compartment is in the hull for rods, guns and game.

Construction and operation of the airboat is

fully described in 4 large drawings and an instruct- ~ ion manual.

Price: $5.50 Incl. First Class Postage

AEROSYSTEMS

PALMER

Fan-tastic, which has been under development for over 2 1/2 years, represents the ultimate in compact, quiet, efficient, high performance personal use surface skimmers.

The craft is an example of modern aerospace "systems" engineering in

which all components of the vehicle are optimized with respect to their effect on the performance of the whole vehicle. As a result, a relatively solidly built engine of only 8 horsepower could be used to give performance equivalent or better than that obtained by other vehicles which

use frantically tuned, lightweight engines of 2 to 5 times the power.

The vehicle is capable of speeds of 30 mph on smooth land and 25 mph over water. Specifications and over water performance are shown below.

SO/50

THRUSTDRAG. LI

Gross weight 440lb

Useful load 260lb

Empty weight

1801b

Power (Briggs and Stratton four-cycle) rated 8 hp at 3600 rpm

Power split, thrust/lift Max power loading Length

Beam

Cushion area

Fuel consumption, 18 mph normal cruise, sea level

still air

Refusal gross weight 470lb

(maximum weight over hump,

still water, sea level air)

7 hp at 3300 rpm

63 Ib/horsepower 11 ft

7ft 54 ft2

34 stat miles/U.S. gal

SPEED, STATUTE MILESlHR

The prototype was built using a hand power drill, sabersaw, a $25 solid oxygen brazing torch and ordinary hand tools. The hull is a simple eggcrate structure to which two styrofoam logs are attached to provide puncture proof, positive flotation. The craft can be built for as little as $350 if care is used in purchasing a used engine or up to $470 if Palmer Aerosystems new parts (engines, propellers, fans, drive components) are purchased rather than built from the plans.

The craft can be dismantled and placed a.top an auto in 5 minutes 15y One person.

Fan-tastic has appeared on television and its exceptional performance

was reviewed in an American Institute of Aeronautics and Astronautics symposium on experimental aircraft (June, 1975) and its noise characteristics were studied in a U. S. Dept. of Agriculture symposium on off road

vehicle noise. Magazine articles on it have appeared in the August,

1974 issue of "Hovering Craft and Hydrofoil" and the September, 1974 issue of "Sport Aviation".

Construction and operation of the craft is completely described in 4 large construction drawings and instruction manual which contains

a material list and price sheet for Palmer Aerosystems supplied parts.

Price: $9.50 Incl. First Class Postage

Fan-Tastic Two is capable of taking 450 pounds payload into wilderness wetlands, enough

_nayload for two average size lults plus gear for overnight

'trips, or if a week or two in the wilds is desire~, 20-25 mph cruising speeds will get Lo t s of camping equipment into

"-..Jase camp and still provide wetlands transport for two.

Fan-Tastic Two was designed with the same philosophy as the original Fan-Tastic. A heavy duty 4 cycle, 16 Hp. garden tractor engine powers ';he vehicle and all components

~are easy to obtain. Simple hand tools, a 1/4" drill, a s-atrenraw and a$~5'-MAPP gas +or-cn are-all that--io-r€qtri-r-e&'-1'~r veh-i-e-l-e ass-em17ly.

Engines, drive components, and rotor sets are available from Palmer Aerosystems.

Fan-Tastic Two is unique in that the air cushion is divided into a low pressure forward section and a high pressure aft section, allowing virtual elimination of annoying spray over the bow, while leaving a smoking mist high in the air behind.

~he craft costs from $500 to $900 to build, depending on the ability of the \,_uilder to find used parts (The engines frequently outlive the equipment they are installed on.)

A special section is provided for those who are willing to sacrifice basic reliability of the prototype and its 32 mph over water and 38 mph overland top speeds for more performance by installing a snowmobile engine of 25 to 40 Hp.

The plans consist of 4 construction drawings plus a 16 page instruction manual which is loaded with pictures of the prototype plus pictures of models showing several steps in hull construction and skirt configuration.

Price':' $l6':-OO-;--Includlng'-Plrst' Class~-ostageu: S. Can. ,---

(Foreign, Add §2.00 for AirmailJ SPECIFICATIONS

8251bs. 4501bs. 3751bs. 14Hp. 13.5 Ft. 7.8 Ft.

0-23mpg.

Gross Weight Useful Load Empty Weight

power (16 Hp Tecumseh) Length

Width

Fuel Cons., Cruise Noise, Wide Open

Throttle at 50 Ft.

Refusal Gross Weight (Maximum Weight that can be planed from

stop in deep water.)

Top Speed, Still Water 32mph/22C Still Air/Loading 27mph/45C

80dB(A)

9201bs.

THREE NEW SERVICES FOR FAN-TASTIC SEV BUILDERS

While Fan-tastics have been successfully completed entirely with-" out help beyond the planset, a

photo supplement has been prepared '-'

to augment the pictures in the

requested by some builders.

15 3 X 5 photos with written description: Price, $5.00

library service has been started for Fan-tastic plans pur chas er-s only.

A 5 1/2 minute super 8 rom. film oLEan-tastics in action is available. Locate a projector first (They can be rented from a camera store.) Then order this service.

Service Fee: $5.00 plus your return postage.

A photo album of Fan-tastics in operation is available which also hlcludes articles and technical papers.

Service Fee: $3.00 plus your return postage.

These latter two items must be returned as they contain not only photos of

'the prototype, but material from builders which is irreplaceable. Maybe some day you can add some material. These albums may become the nucleus of some type of club activity around building and operating sevs if enough people contribute. For this library service to work, the material must

be returned.

FAN-TASTIC PARTS KITS.

A. Drive $44
B. Rotor Set $120 A
C. Skirt Mat'l $46
D. Cement $7 ,
E. Idlers $34
8 and 10 Hp ,
Briggs engines
not shown, price
on request. c

FAN-THSTIC

March, 1976

Errata

Sheet 1: The

3/4" shown for the rudder height should read 44".

Bill of Materials: The styrofoam dock flotation log is 9 feet long.

The floats may be cut from any 1 1/4 pound per cubic foot styrofoam.

Do not gl.aas the floats, and do not use urethane for the floats.

Design Changes

Three years of operating experience has shown the air drive unit to be exceptionally reliacle. However, some weaknesses have shown up in the hull structure. (See sheet 1) The 5/16" X 3 1/4" frame stock should

be changed to 1 X 3 (3/4" X 2 1/2" nominal) and the hull outer edge should be changed from 3/4" X 3/4" to 3/4" X 1 1/2" laid flat. The curved portions should be laminated from 1/4" thick stock. The above changes will prevent small kids from breaking the frames by walking on the deck and prevent items such as large rocks and fence posts from doing major damage when they run into the hull.

Rudder Bellcrank and Shuttle

A further explanation of the rudder mechanism is required. The builder will note that the bellcrank, which is glassed to the rudder, projects out the right side of the rudder. The rudder pivot passes through the center of the rudder shuttle, which attaches to both bellcrank and stick as the diagrammatic view from above shows.

ontrol Stick

FAN-TASTIC 2 place

Fan-tastic payload can be increased to 350 pounds by using the new Briggs vertical shaft 10 horsepower engine in conjunction with an increase in hull length of 24". To leng:then the hull, add one extra frame and 24" added length just ahead of the fan cutout, where all hull elements are parallel. Remember that the side skirts and floats have to be lengthened, also. The aft end of the toe box should be placed 93 inches ahead of the aft end of the hull to achieve balance for tandem seating.

F .-\1\ -'I AS TI C

April, 1976

MANDATORY DESIGN CHANGE

After some 300 hours of operation, the four bolts holding the prototype fan failed, resulting in loss of the fan and damage to the hull and fan shroud. As such a failure could cause a loss of cushion air which is much more abrupt than if the engine were to stop running, with possitle ejection of the operator as the outcome, the colts should ce replaced with 5/16 inch heat treated bolts. (Look for the heat treatment marks on the bolt head.)

Completions

The designer should ce notified of vehicle completions so that the very latest advisories may be sent to the operators. A short super eight

mm. film of the completion showing the operating vehicle, type of terrain being operated on, and something characteristic of the geographic area

or country of the builder would be appreciated. The film should be original, not copied, so the emulsion will be on the correct side. When enough films are obtained, they will be spliced together and circulated to builders and operators at 't.h e i r- request. Also good black and white glossys would be appreciated for future use in brochures.

Float Wear

Loss of material from the float bottoms may be reduced if a 3/4 inch by

1 1/2 inch strip of wood is bonded edgewise into the float bottom. Leave 1/4 inch protruding beneath the float. As an added benefit, the floats will slide over obstacles better.

Skirt lr£ear

To improve skirt life, or rejuvenate a worn skirt, tond a 10 inch wide ~ band of skirt material to the skirt running surface. A third layer may be added to the corners in high wear areas. (Note, the prototype has gone some 5000 miles and is still not ready for a skirt "half sole".

FAN-TASTIC

August, 1976

FAN-TASTIC 2 Place, Cont'd

Although the payload of the stretched version of FAN-TASTIC is greater than some 2 place machines, the craft should be regarded as a light duty machine for good conditions only. Naturally, the shorter version of the vehicle will handle better. A craft which is powered with a 16 horsepower garden tractor engine has been flying since January of this year, and is still under development. It has a 30 mph. top water speed, 500 lb. payload and gets 23 mpg. at normal 20 to 25 mph. cruising speeds.

Skirt Fine Tuning

Recent work with a local completion has indicated the following:

The flap that covers the skirt drafun hole should be extended to cover the hole by 1 1/2 inches. The modification, as shown here, vi) 11 improve the vehicle skirt purging after the vehicle lifts

The bow skirt should be cut out exactly edge should be trimmed 1 inch, at the craft centerline, the trim tapering to nothing at the quarter skirts. Skirt assembly is simplified if the halves of the bow skirt are first attached to the quarter skirts, and later joined at the vehicle centerline when the

skirt is assembled to the hull.

/Old Flap

{ Shape

off water, markedly reduce rough water drag and spray caused by the drain hole snagging on the water surface, and improve handling.

r Drain Hole

the lower

Trim 1 inch