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The Lonestar Kit Helicopter
by Adam Aiken

From Pacific Flyer Magazine,
September 2005 Edition


The 90's brought a myriad of new kit helicopter designs to the market including Cobra Helicopter's turbine powered Predator and Rotax powered Mustang, the Angel CH7, the Furia/Skylark, the Mosquito and Masquito, Rotorway Execs and the unfortunate but ever popular Mini 500, just to name a few.

There was much to be said for and against the many new releases hitting the market in the USA. A lot of them were way before their time as the general public, although fascinated by them, were not ready to support their sales. Many vendors regretfully closed up shop causing some of the early and most innovative designs to be lost for ever. They were the pioneers of what is now a booming industry around the world. Since then, modern technology has enabled lighter and more powerful models to be produced and also the ability for individuals to build from plans.

I have been following these helicopters since my early teens when my father took me for a joy flight in a Hughes 500. I started buying every set of plans and information pack available and subscribed to most of the US based experimental aircraft magazines.

It wasn't long before I came across the little known compact helicopter, the Lonestar, developed in Texas by Ken Rehler of Star Aviation Inc which began in March 1990. In July the first prototype was displayed at the 28th Annual Popular Rotorcraft Association Convention, where it received a PRA award. It sported McCutchen composite blades, a chromoly airframe with standard swash plate and fly bar servo blade rotorhead, Rotax 582 and wheeled tricycle style landing gear. The prototype had a unique feature of having the tail rotor not extend past the main rotor disk diameter as did the early Adams Wilson 'Flying Trumph' also known as the "Choppy" of the 1950's and some of its offspring such as the first Skytwisters. This feature, amongst others was touted by the late B. J. Schramm of Rotorway fame, but proved to be unfounded in flight tests. This Lonestar first flew on October 18, 1990.

The designers now with a proof of concept craft set out to further improve upon their cute little chopper and set it into production. The first kit parts were shipped to customers in the summer of 1991. The original model (through Kit 36) was produced until April 1992 when production began on the current model.

The final design resulted in an all aluminium-framed model sporting a more powerful and reliable Hirth F30 rated at 95 hp providing ample power and improved reliability. Simple layout for easy inspection and low maintenance components were also incorporated. Other changes included a through shaft control system, elastomeric main rotor thrust bearings, new standard styling landing gear, a cog belt tail rotor drive eliminating slipping V-belt drives and expensive, heavy gearbox drive systems.

Star Aviation's demonstration helicopter was completed in March 1993 and in October it received the "1993 Best Rotorcraft Award" at the Experimental Aircraft Association Southwest Regional Fly-in.

Lonestar Aviation was on a winner with a brilliant new design when devastation struck. After successfully delivering a number of kits, their factory was completely destroyed in severe floods losing all stock, production equipment and drawings.

The decision was made to return to the 9 to 5 grind, as starting from scratch again didn't seem like an option. Fortunately their prototype that was mainly used for air displays, wasn't involved in the floods and continued to build 70 hours of flight time before being put up for sale. It was a station owner in Quilpe, Queensland that was the lucky recipient of the Lonestar LS-50 with all factory upgrades and modifications including the frame change to improve rotor shaft support and stability.

Unfortunately, due to poor health the station owner was only able to add another 18 hours on the clock, mainly through monthly run-ups. I had been fascinated for years with this particular craft due to its compact size and innovative design features. I had been fortunate in obtaining an information pack for the Lonestar early in the 90's and was obsessed with finding one.

It was quite by accident that I picked up the commercial Aviation Trader newspaper to round off a credit card purchase when I came across the Lonestar. I couldn't believe my eyes !. I immediately rang and claimed the craft as 'sold'. My wife and I flew to Brisbane where we hired a Ford one ton ute and left for Quilpie, west of Charleville (friendly people and great local pub!). The trip in itself was another story but needless to say, after some very strange looks by fellow motorists, we got the Lonestar home safely to Victoria. Other than some minor cleaning and checking she was ready to go. It didn't take us long to realise that the Lonestar purchase may have been a little premature since I have only a fixed wing RAA licence and am yet to commence rotary wing training. As the new experimental helicopter licensing requirements are not yet in effect, I would require a full helicopter PPL to fly and had just invested my funds it the Lonestar.

It is with regret that we have decided to sell the Lonestar in an effort to fund my rotary wing licence ambitions, although I am happy to say that I once owned a Lonestar and had the chance to study this magnificent little machine.

I'm not sure where this will lead me but all I know is that I want to fly and fly I will. The Lonestar is for sale at $29,500 and I welcome any serious buyers to contact me regarding its sale.

Specifications
Star Aviation's single seat helicopter, the Lonestar with Australian VH registration and CASA Special Certificate Of Airworthiness "Experimental Certificate". Features a through shaft control system, high ground clearance skids, McCutchen composite main rotor blades, Hirth F30-EP2 two stroke 4 cylinder 95 hp engine, 2 x 2 inch aluminium airframe, removable skids with 2 different ground handling wheels configurations, compact size, with long range fuel tanks (approx. 18 US gallons, consumption at cruise approx 5.6 gph at gross weight).

There are a number of kits still flying around the world, particularly in the USA and Japan. The original designer is still contactable in the US although, I believe he lost all documentation relating to the helicopter in the flood. A new compass has been fitted.

There is no cabin although one can be fabricated. It comes with the original factory documentation/manuals and is currently registered in Australia VH-AMU. It fits in a standard single car garage. It can be transported on the rear of a one ton tray ute or by trailer. The purchaser accepts all responsibility for the use and operation of this craft. Empty weight 470 lbs/210 kgs, gross weight 920 lbs/415 kgs, rate of climb at gross weight, 1,000 fpm. Cruise speed (no cabin) 65 mph/105 kmph, Max speed 95 mph/150 kmph, VNE 100 mph/160 kmph.

Cruise speed will increase by 10 mph/16 kmph with cabin fitted. HIGE 6,000 ft/1,830 m, HOGE 5,000 ft/1,525 m, service ceiling 9,500 ft/2,895 m. 100% safety record on all Lonestars.

For enquiries contact Adam Aitken on 0411 337 550 or A/H 03 9748 4437 Hoppers Crossing, Victoria. Email afaitken@yahoo.com