Discoverer Project
Construction Pictures of the GEO Conversion

Part II
After about 45 hours of runtime since I installed the GEO I have had numerous minor failures of various parts.  I have had to replace the exhaust system and alternator due to salt water corrosion, I have worn out 5 or 6 fan belts and I have had a piece of the radiator vibrate loose and drop through and destroy the original fan.  I have decided that the original engine stand is not sturdy, strong or rigid enough to handle approximately twice the original HP and 80% more thrust than is specified in the original design.

So, I am now building a stronger and more rigid engine stand.  I am also going to build a new prop guard and also incorporate a complete engine cover also.  The following pictures will show you the steps I have taken during this conversion.  I have not added this section to the daily log as I consider the craft completed and this is just another  improvement on the way to my "perfect" hover!

Enjoy the photos and BE CAREFUL if you decide to increase your power beyond the normal specified limits!
Get some help or advice if you are not familiar with doing your own designing.  Never risk harming yourself or someone else needlessly!
HAPPY HOVERING!!!
 

Here is the basic design of my new GEO engine stand.  I will be using four vertical tubes to support the prop shaft, I will drive the prop shaft directly off the engine, then drive the fan off the prop shaft.  The main engine stand/fan bearing tubes will be 1.25" and the rest is 1".  There will be more bracing to keep the whole thing more rigid than I had before.

The next few pictures show you the base framework of the new drive system stand.  This is a view form the port rear of the craft during a temporary test fit.

There is a "box" frame in each corner of the rear deck.  I have welded two tabs on each frame so I can thru-bolt to the wooden framework inside the rear "transom".  There is also a piece of angle welded to the forward tube of the box frame with bolts going thru the wooden stringer that goes across the rear deck.

Here is a picture of the incomplete forward end of the stand.  I will be welding a piece of angle across these tubes so I can secure the front of the stand.  I will make the piece of angle a bit wider than the front tube so I can attach the guard braces to it later.

A view looking down on the rear deck.  Notice the offset of the fan duct.  This was in the original plans to help compensate for the effects of torque on the craft from the engine and prop.

This is the stand base ready for the next step in the assembly process.

I cut and drilled the two fan bearing cross members so I could locate the position of the fan.  I marked the main rails and tack welded them in.  Here I am rechecking the position of the shaft and bearings.

Another view of the fan bearing cross members, shaft and bearings after I tack welded them together.

After I test fit the fan and the pulley I realized the pulley would be higher than I wanted.  I cut out the tack welds and added a 3/4" piece of angle to the end of the cross members and welded the piece of angle to the bottom of the main rails.

Now the fan bushing sits tight up against the bearing and the trailing edge of the blades are right at the bottom edge of the duct.  The pulley sits a little lower now and I think it will fit a little bit better under the engine.

I have the two forward vertical prop shaft frame supports tack welded in place.  The board is clamped between them to hold them so I don't break the tack welds.

This is the prop shaft frame.  It will be welded on top of the four vertical tubes and will support the pillow blocks.  The bolt hole bushings have also been welded in place.