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VSKYLABS Mini-500 - Pilot Operating Handbook (POH)

VSKYLABS Test-Pilot: Revolution Mini-500 Pilot’s Operating Handbook
WARNING: DO NOT USE FOR REAL FLIGHT OPERATIONS

VSKYLABS Revolution 'Test-Pilot': Mini-500

VSKYLABS 'Test-Pilot': Revolution Mini-500

MANUAL / POH

Edition rev.005 (issued March-2023)

For use with X-Plane 12 flight simulator

Advanced simulation of the Revolution Mini-500 Helicopter

The VSKYLABS development of the Revolution Mini-500 project for X-Plane flight simulator was acknowledged by its real-world designer, Mr. Dennis Fetters. However, it is an independent VSKYLABS project which is not related, affiliated and/or endorsed with the 'Fetters Aerospace Company' and/or Mr. Dennis Fetters.

WARNING

For Information Only - Real World MINI-500 Manual Reference

Does not applied with the VSKYLABS virtual simulation model

The Mini-500 kit helicopter you are about to operate is not a toy. It is a real helicopter. As with any air vehicle, proper training is essential. Any attempt to operate this helicopter without first receiving proper and complete training could result in serious injury or even death! This operator's handbook must be read and understood before any operation of the Mini-500 kit helicopter is attempted. The Mini-500 kit helicopter must always be operated within the limits of the operator’s handbook, governmental aviation regulations, and plain common sense. Do not alter or modify the design of the Mini-500 kit helicopter or any of its parts.

VSKYLABS Aerospace Simulations / Copyright Ⓒ2025 JetManHuss - VSKYLABS. All rights reserved. No part of this publication may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other noncommercial uses permitted by copyright law. For permission requests, write to the publisher, addressed “Attention: Permissions Coordinator,” at the following address: contact@vskylabs.com

INTRODUCTION

This is a comprehensive instruction and Pilot’s Operating Handbook guide for the VSKYLABS 'Test-Pilot': Revolution Mini-500 Project for X-Plane 12.

The project is introducing the innovative (for its time, back in the 90's) Kit-Built Revolution Mini-500 helicopter.

Warning - For use with flight simulation only:

This Manual is based on the actual, real-world Revolution Mini-500 helicopter manual. However, it is presented here as the instruction manual of the VSKYLABS 'Test-Pilot': Revolution Mini-500 virtual simulation model and should NEVER be used as a reference for real flight operations.

The real Revolution Mini-500 vs the VSKYLABS Mini-500:

The original Mini-500 Pilot’s Operating Handbook was chosen to become the core of this VSKYLABS Mini-500 POH.

The VSKYLABS Mini-500 simulation was developed to follow the real Mini-500 handling and performance characteristics. It is a highly engineered, robust helicopter simulation model which make use of X-Plane 12 sophisticated flight dynamics and physics simulation, extracting it to its limits. As a result, the VSKYLABS Mini-500 simulation demonstrates highly accurate and authentic flight dynamics characteristics of the Mini-500.

Simulated systems:

The VSKYLABS Mini-500 features X-Plane 12 latest native features, systems and physics. This assures a 'high airworthiness' in X-Plane, throughout its update process. Some systems may be restricted to X-Plane’s default systems algorithms.

X-PLANE GENERAL SETUP NOTES:

  • The VSKYLABS Mini-500 is equipped with skids-wheels. These are dummies and are visible only when the aircraft is cold and dark. Once the electrical bus is powered, these will not be visible any longer.
  • Weight and Balance: The empty weight of the Mini-500 is 485 lbs. The VSKYLABS Mini-500 is set be initiated with the pilot's weight by default, as a fixed weight of 170 lbs.

  • Throttle Governor: Just like the real Mini-500, the VSKYLABS Mini-500 is fully flyable without a throttle governor. In this case, you will have to manage both engine and rotor RPM manually. This can be done easily with the use of professional / full helicopter controls for flight simulators. However, the VSKYLABS MINI-500 is equipped with a helicopter-type throttle governor that keeps rotor RPM at 100% as long as the throttle is set above 70-80%. This allows a more 'easy' operation of the helicopter, when throttle and collective control axes are lacking in your Joystick hardware.
  • Flight model calculation rate: In X-Plane, there are situations in which light-weight 'spring-loaded' aircraft may induce fluctuations of the flight dynamics model, resulting in 'jumps' of the aircraft (mostly noticeable when it is on the ground). This issue is not a bug, but a normal behavior of X-Plane, especially when the CPU/GPU are struggling on lower-end PC configurations. To eliminate the issue go to X-Plane settings ---> 'General' tab, and increase the Flight models per frame rate:

VSKYLABS MINI-500 COCKPIT AND INTERACTION:

VR Interaction zones:

The green zones shown in the screenshot above are representing the interaction areas for mouse and/or VR touch controllers.

IMPORTANT:
Collective has TWO interaction zones:

  • Forward zone is for collective control (up/down).
  • Aft zone is for throttle control (left/right).


Cockpit walkaround A:

Cockpit walkaround B:

Warning light test:

Press on the test button:

  • The lights should come up, and an alarm buzzer should be triggered.
  • Note#1: Low RPM light is enabled once the Master Power switch is ‘ON’.
  • Note#2: Low Rotor RPM buzzer alarm will be activated between 82% to 90% RPM.

Throttle Governor operations:

Just like the real Mini-500, the VSKYLABS Mini-500 is fully flyable without a throttle governor. In this case, you will have to manage both engine and rotor RPM manually. This can be done easily with the use of professional / full helicopter controls for flight simulators. However, the VSKYLABS MINI-500 is equipped with a helicopter-type throttle governor that keeps rotor RPM at 100% as long as the throttle is set above 70-80%. This allows a more 'easy' operation of the helicopter, when throttle and collective control axes are lacking in your Joystick hardware.

VSKYLABS EXPERIMENTAL-LSA AUTOPILOT

Some of the VSKYLABS aircraft are equipped with a custom experimental/LSA autopilot system.

The autopilot can maintain flying altitude, flight attitude (roll and pitch) and it is also features a turn/bank and slip indicators.

SECTION 1. GENERAL


Mini-500 Specifications:

Power Plant....................Rotax 582, water cooled, 67 hp.
Seats..........................1
Gross Weight...................840 lbs.
Empty Weight...................485 lbs. (approx.)
Useful load....................355 lbs.
Fuel capacity..................14.7 U.S. Gallons

Oil

Injection oil..................2 cycle oil, 50:1, TSC-3 specs
Tail rotor gear box............Mobilube SHC 80W - 140 gear
                               Lubricant, or equivalent (3 ounces)

Main Transmission..............Mobilube SHC 80W - 140
                               Gear Lubricant, or equivalent
                               (1 quart)

Main Rotor

Articulation...................Semi-rigid teetering underslung
Number of blades...............2
Diameter.......................19 feet 2 inches
Precone angle..................2 degrees
Blade cord.....................8 inches
Tip speed @ 100% RPM...........547 FPS or 373 MPH
Blade RPM @ 100% RPM...........546

Tail Rotor

Articulation...................Free to teeter, rigid in plane
Number of blades...............2
Diameter.......................3 feet 10 inches
Precone angle..................2 degrees
Blade cord.....................4 inches
Tip speed @ 100% RPM...........536 FPS or 365 MPH
Blade RPM @ 100% RPM...........2671

SECTION 2. LIMITATIONS


Max. level airspeed at sea level, standard day........100 KTS/115 MPH
Velocity never exceed (VNE)...........................104 KTS/120 MPH
Calculated Retreating Blade Stall.....................130 KTS/150 MPH
Max. airspeed in turbulent air..........................65 KTS/75 MPH
Max. sideways, rearwards airspeed.......................17 KTS/20 MPH
Slope landing limits........................................5 degrees
Fuel requirements........................................87-92 octane
                                                   Unleaded auto fuel
                                               (no alcohol additives)

Day VFR flight only (unless properly equipped and certified)
Flight with cabin doors removed is permitted.

Max. gross weight.............................................840 lbs.
Minimum pilot weight..........................................120 lbs.
Maximum pilot weight..........................................250 lbs.

Low G maneuvers prohibited.

CAUTION

Avoid abrupt pull-ups or pushovers. When a pull-up is followed by a pushover, you may unload the rotor system, causing a weightless or low G condition. If allowed to progress too far, loss of control or severe mast bumping may result. The consequences could be fatal.

If you inadvertently enter a low G condition and the aircraft starts to roll, gently apply aft cyclic to reduce the weightless feeling before using lateral cyclic to stop the roll.

Instrument markings:

Color code for instruments markings:

GREEN..................................Normal operating range
YELLOW.............................Cautionary operating range
RED..................................Maximum operating limits

Airspeed:

Red line......................................104 KTS/120 MPH

Water Temperature:

Green.......................................130 to 184 deg F.
Yellow......................................185 to 202 deg F.
Red line...........................................203 deg F.

Rotor RPM:

Low red line..............................................90%
Low yellow.........................................90% to 96%
Green.............................................96% to 104%
Upper yellow.....................................104% to 110%
Upper red line...........................................110%

Engine RPM:

Green.............................................98% TO 102%
Red line.................................................104%

Exhaust Gas Temperature:

Green.....................................1000 to 1199 deg F.
Yellow....................................1200 to 1299 deg F.
Red................................................130 deg F.

SECTION 3. EMERGENCY PROCEDURES


Engine failure-General:

  • A change in engine noise and a left yaw may be the first indication of engine failure.

CAUTION

Following engine failure at high speed, aft cyclic should be applied simultaneously as the collective is lowered, since the helicopter will have a tendency of nose over.

Engine failure below approximately 10 feet AGL:

  • Maintain level altitude with cyclic.
  • Apply right pedal as required to prevent yawing.
  • Do not reduce collective.
  • Increase collective just before touchdown to cushion landing.

Engine failure between 10 and 500 feet AGL:

  • Lower collective to maintain rotor RPM.

NOTE

The amount and duration of collective reduction depends upon the height above the ground when the engine failure occurs.

  • Adjust collective to maintain rotor RPM in the green.
  • Maintain airspeed until ground is approached then begin a cyclic flare to reduce forward speed.
  • At approximately 8 feet AGL, apply forward cyclic to level aircraft and start raising collective to cushion landing. Touch down with aircraft level and use pedal to maintain heading.

Engine failure above 500 feet AGL:

    1. Lower collective to maintain rotor RPM and enter normal autorotation.
    2. Establish a steady glide at approximately 60 mph (52 knots).
    3. Adjust collective to maintain rotor RPM in the green.
    4. Select suitable landing area, and if altitude permits, maneuver so that landing can be made into the wind.
    5. A restart may be attempted at pilot’s discretion if time permits.
    6. If a restart is not possible, turn off unnecessary switches and shut off fuel valve.
    7. At about 35 feet AGL begin a cyclic flare to reduce forward speed.
    8. As aircraft settles to about 5 feet AGL, use forward cyclic to level aircraft, and increase collective to cushion ground contact.
    9. Use pedals to maintain heading, and touch down in a level attitude with nose straight ahead.

Engine fire on ground during start:

    1. Continue cranking to start engine, which should suck flame and excess fuel into engine.
    2. If engine start, run at idle for a short time. Then shut down and inspect for damage.
    3. If engine fails to start, turn off ignition, fuel and master switches.
    4. Extinguish fire and inspect for damage.

Engine fire in flight:

    1. Enter autorotation.
    2. Shut off fuel valve.
    3. Execute autorotation landing.

Electrical fire in flight:

    1. Master switch off.
    2. All other switches off.
    3. Land immediately.
    4. Extinguish fire and inspect for damage.

Tachometer failure:

    1. If the rotor or engine tachometer fails, use the remaining tach to make a normal landing.

Water temperature over red line:

    1. If the water temperature starts to rise steadily and continues above the red line, this indicates there is a cooling system malfunction.
    2. If, through forward airspeed, enough ram air can be forced into the air scoop to keep the water temperature close to the red line, make a normal landing immediately. Turn the ignition switch off as soon as you are safely on the ground.
    3. If water temperature can not be controlled, enter autorotation, turn off ignition and master switches, and make an autorotation landing.

Tail rotor failure during hover:

    1. Failure is usually indicated by right yaw which cannot be stopped by applying left pedal.
    2. Immediately close throttle and perform hovering power off landing.
    3. Keep aircraft level and increase collective just before touchdown to cushion landing.

Tail rotor failure during forward flight:

    1. Failure is usually indicated by right yaw which cannot be corrected by applying left pedal.
    2. Adjust forward airspeed, collective, and throttle to maintain forward flight.
    3. Fly to a suitable area and perform a shallow approach to a run on landing. Use throttle to maintain heading during touchdown.
    4. If sideslip becomes excessive or aircraft tends to spiral, roll off throttle and perform autorotation landing.

Drive train failure:

NOTE

A failure of any of the drive train components will be recognized by the engine RPM going to the red line, and the rotor RPM decreasing.

    1. Autorotate.
    2. Throttle off, to prevent engine damage from over revving.

SECTION 4. NORMAL PROCEDURES


Pre-flight checks:

  1. Remove tie-downs and covers.
    1. Turn blades 90 degrees to tail boom.

  2. Cabin Interior:
    1. Instrument panel - screws in place and secure.
    2. Master switch on.
    3. Landing light on, then off.
    4. Nav. light on, then off.
    5. Raise collective, low rotor alarm should sound.
    6. Master switch off.
    7. Pedals - secure, move freely with no binding.
    8. Cyclic boot open, examine control linkage, close boot.
    9. Seat, seat belt, shoulder harness - condition and security.
    10. Fuel - check level.
    11. Left door - condition and secure.

  3. Rotor blade check for - general condition, nicks, disbonding.

  4. Left landing gear check - condition and security.

  5. Belly scoop intake check - free of debris.

  6. Left access door remove and check:
    1. Main transmission oil level - should be above sight glass.
    2. Main transmission for oil leaks, mounting studs secure, no cracks.
    3. Chip detector (if installed), short center stud, master switch on, check chip light on, master off.
    4. Injector oil level, reservoir secure, no leaks.
    5. Flight controls for condition and security, nuts tight, safeties installed, rod ends for excessive play.
    6. Wiring harness - chafing, security.
    7. Collective - security and freedom of movement.
    8. Centrifugal clutch - main bolt slippage mark.
    9. Main drive belt - condition and tension, center of upper sprocket.
    10. Engine - spark plugs and caps, oil level, magneto wire secure, carburetors and filter secure, mounting bolts secure, coolant hoses and fuel lines for chafing.
    11. Fan belt and fan - condition.
    12. Frame - no cracks.
    13. General condition of engine compartment.
    14. Left access door - install.

  7. Turtle deck - condition and security.

  8. Tail boom - no wrinkles.

  9. Tail rotor check for obvious damage, gearbox for oil leaks, condition and security of linkages.

  10. Chip detector (if installed) - short center stud, master switch on, check chip light on, master off.

  11. Tail surfaces - condition and security.

  12. Fuselage right side check condition.

  13. Right landing gear - condition and security.

  14. Rotor blades - check for general condition, nicks, disbonding.

  15. Rotor head check - condition and security, oil leaks from hubs, pitch change links rod ends for excessive play.

  16. Right door - condition and security.

  17. Windshields check for cracks or scratches.

  18. Pitot static tube check not clogged or bent.

Before staring:

  1. Seat belt and shoulder harness...............on and adjust
  2. Altimeter........................set to field of elevation
  3. Avionics...............................................off
  4. Doors...............................................secure
  5. Friction...............................................off
  6. Flight controls check..............full travel, freedom of
                                           movement,no binding
  7. Friction................................................on


Starting:

  1. Fuel valve..............................................on
  2. Prime.........................................if necessary
  3. Cyclic and pedals...............................neutralize
  4. Collective.......................................full down
  5. Throttle.............................................close
  6. Headset.................................................on
  7. Master switch...........................................on
  8. Area.................................................clear
  9. Ignition switch.........................start then release
  10. Avionics................................................on
  11. Let engine idle until water temperature registers on gauge


Run up:

  1. Collective raise slightly.....low rotor alarm should sound
                                              Lower collective
  2. Throttle.............................set rotor RPM to 100%
                                 (check low rotor light out at
                                            Approximately 95%)
  3. Dual ignition check........left then both, right then both
                                   (engine RPM should not drop
                                   below bottom of green area)
  4. Throttle close...................needles should split, set
                                                  Back to 100%


Take off:

  1. Adjust friction as desired.
  2. Set rotor RPM to the top of the green area. With cyclic and pedals centered, slowly raise the collective. Under most conditions, throttle correlation will rais rotor RPM up into the yellow as you become light on skids. This is normal and, as you become airborne, RPM should settle down into the green area. With conditions of high density altitude and/or high gross weight, additional throttle may be required to maintain rotor RPM in the green area.
  3. Take off should be accomplished per height velocity diagram.
  4. Maintain rotor RPM at the top of the green below 500 feet AGL.


Shutdown:

  1. Collective full down............................friction on
  2. Cyclic neutral..................................friction on
  3. Pedals..............................................neutral
  4. Throttle........................idle until water temp cools
                                   To approximately 150 degrees
  5. Avionics................................................off
  6. Ignition switch.........................................off
  7. Master switch...........................................off
  8. Perform general walk around inspection.

SECTION 5. PERFORMANCE


Hover in ground effect................................7000 feet
Hover out of ground effect............................7000 feet
Service ceiling.....................................10,000 feet
Normal cruise.................................75 MPH (65 knots)
Maximum range at cruise...................225 st. miles / 3 hrs                                                                                 (No reserve)
Best rate of climb............................45 MPH (40 knots)


SECTION 6. WEIGHT & BALANCE

The center of gravity (C.G.) of any aircraft is critical for safe operation. To determine that the C.G. of your Mini 500 is within allowable limits, the following procedure must be performed prior to attempting to fly your aircraft:

Step 1

The first step is to weigh the helicopter. Before weighing, the helicopter must be complete, with all permanent equipment installed.

    1. Full coolant.
    2. Full injector oil.
    3. No fuel.
    4. Enclosed area, no wind.

Step 2

Place a calibrated and accurate scale under each weighing point (sta. 43 and sta. 76 left and right side).

Step 3

Level aircraft both laterally and horizontally by shimming under scales.

Step 4

Record scale readings on Aircraft Basic Weight Worksheet.

Step 5

With the information obtained in step 4, and your body weight, use the weight and balance worksheet to determine the amount of ballast weight needed (if any), to bring the C.G. location to 61 inches.

SECTION 7. REVOLUTION MINI-500

DESCRIPTIVE DATA


Composites:

  1. All composite components are made of pre-preg epoxy fiberglass.
  2. The cabin, fire wall, side access doors, horizontal and vertical stabilizer, center console, and seat, have a Klegacell foam core sandwiched between 2 or more layers of pre-preg.
  3. The belly pan, turtle deck, and instrument box are 2 layers of pre-preg without foam core.
  4. All composite components are vacuum bagged and oven cured at 250 deg. F.
  5. When bolted together, the cabin, firewall, center console, and wind shield “T” become an integrated structural pilot enclosure.

Windshields and Plastics:

  1. Formed from shatter resistant polycarbonate.
  2. Instrument panel and plastic trim pieces are vacuum-formed from various thicknesses of ABS plastic.

Frame:

  1. The entire frame is made of 4130 chromolly steel tube. Tubes are cut and notched then jig welded with a heli arc (tig) welder. After being removed from the master jig, all welds are shot-peened for stress relief and inspected.
  2. The frame is the main structural base for all other components. It is triangulated for stress load distribution and has hard mounting points for component attachment.

Rotors:

  1. The main rotor blades have an extruded aluminum leading edge spar, with a machined foam core, and pre-preg epoxy fiberglass outer skin. They weigh 17.6 pounds including a one pound steel tip weight giving very high inertia.
  2. The blades are symmetrical with an 8 degree constant twist. They are 9 feet long with an 8 inch cord. The airfoil thickness ratio (percent of cord) is 12.5%.
  3. The rotor disk diameter is 19 feet 2 inches, and is of the semirigid teetering underslung design. Disk loading at max. gross weight is 2.8 lb. per square foot.
  4. The main rotor hubs are machined from solid billet 6061 T6 aluminum. The spindles are machined from 4130 chromolly steel.
  5. The tail rotor blades have an aluminum hub and spar, and are wrapped in an aluminum skin which is jig clamped and heat bonded with epoxy adhesive film.

Drive train:

  1. Power is transmitted from the engine by a cog type synchronous drive belt to a sprocket mounted on the main transmission pinion. Housed in this upper sprocket is a spraque type overrunning clutch, which gives full autorotation capability. Power is then transmitted from the pinion to the ring gear in the main transmission, thus turning the 4130 chromolly steel tube rotor mast. At 100% the main rotor turns at 546 RPM.
  2. The main transmission has a spiral bevel cut and ground ring and pinion, designed and manufactured specifically for the Mini-500.
  3. The gears are designed to give 2000 hours of life with a safety factor of 1.2.
  4. Power is transmitted to the tail rotor via an aluminum tube drive shaft, which is connected to the main transmission pinion by a flex plate and is supported and spaced evenly from the center by 2 sealed ball bearings. The 90 degree tail rotor gearbox is connected to the drive shaft by a splined coupling. At 100%, the tail turns at 2671 RPM.

Flight controls:

  1. The flight controls are unboosted. The cyclic and collective use aluminum push pull tubes. The anti-torque pedals use a push pull cable. Cyclic and collective mixing is accomplished via the Mini-500’s patented tripple gimmel system, and the appropriate inputs are transferred to the rotor system.

SECTION 8. REVOLUTION MINI-500

CONDENSED CHECKLIST