Building and flying your own helicopter has become a more affordable and practical option with the introduction of the build assist program by Kevin and Enid Lunn of Rotorway International Australia in Queensland. The machines have also undergone some modifications to make them better suited for Australian conditions. Kevin Lunn writes -

When I first started with Rotorway in 2002, the model available from the factory was the Exec 162F. To get it flying in Australia we had to update the airframe and electrical system with a few small fuel system mods to comply with the rules of the time.
The first helicopter is a great machine - VH-CCW has completed over 350 hours and still flying very well with Jimmy Whitfield in Waroona WA.

We then requested from the factory in the U.S. to have the kits updated for Australia and the
Exec 162 FA Series One was born. It included a self draining oil bung, bigger seat belt attachment points and an internally painted tail boom to stop possible corrosion - most of us do live near to the ocean and salty air with a sea breeze - and a long list of other changes.
It weighed in at 460kgs and had a usable load 222kgs so confined area work was to say the least challenging with full fuel and two passengers
The cruise was just a delight with no frictions and no trims to worry about. Hands free flying was par for the course in a couple of words the best helicopter I had ever flown.
But lack of range and the usable load it made cross country flying very challenging with constantly looking for somewhere to get fuel. The instrument panel was not the best with the VSI located right down by the floor and nearly impossible to see.
The water pump was another item that I really wanted to change, as the seals would only last for a bout 50 hours before they needed replacing.
Although it was an easy job to do, it always happened when you were miles away from home. It would not stop you getting home, as it just dribbled a very small amount of coolant over the pump (not a full on leak) - but it was very annoying none the less.

In 2004 after building four more helicopters and commissioning many more we started to make a few more changes to the Exec162FA S1.
With the VSI position changed the panel was now very functional and, with a long list of upgrades from the factory, we released the Exec162FA Series Two in Australia. It has three hours endurance, an electric water pump and was some 31 kgs lighter, giving a usable load of 253kg and a helicopter with very good performance and reliability.

The series two has been a great success for us. Sales have been very good with 10 flying with three long-range versions .The future looks even better.
One of the best things we did was introduce our builder assist program and our customers can now use our workshop with all the tools and accommodation on the property,
They spend six weeks working five days a week then fly home in their new helicopter finished to a very high standard with our experience utilised to its full potential. On average the whole project takes less then 300 hours from boxes to completely finished and flying.

Technology has come a long way and our constant search in the US and Australia to improve our machine has seen us come up with a few world firsts. We have been responsible for the world's first working LED tracking light for helicopters to make a two man job a very easy one man job. These are now sold all over the world as are our long range fuel tanks and electric water pump conversions.
The future for this helicopter is assured with over 4000 world-wide and 100 in Australia and New Zealand to date.

I got involved with these machines for reasons that most pilots are familiar with - keen desire to fly but never enough money. It was a fairly familiar progression from models as a kid to hang gliding at age 16, gliders, fixed wing then helicopters. I built my own Rotorway and found it to be a reliable , affordable and did not cost the earth to maintain - so we went to US and bought the dealership.
Now 5 years latter with more than 650 logged hours on Rotorway and eight helicopter built using builder assist and the commissioning of 25 owner built Execs we have the ability to help all no matter your experience or mechanical abilities to get you to the flight line from $68990USD and in less time than ever before.