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RSG GyroFly, Tågarp (2026)

20/10/2026

🔧 TECHNICAL SNIFFER | RSG DIAMOND

Why Aluminium? And Why No Welding?

Today, we have taken another important step towards building the first RSG Diamond prototype.

Our shipment of aluminium profiles has arrived — the material that will form the main load-bearing structure of our gyroplane.

From the very beginning, we established one fundamental principle: the structure should not only be strong and lightweight, but also practical to manufacture using relatively simple workshop equipment.

That is why we chose 6082-T6 aluminium alloy and a bolted frame construction instead of welding.

Why this approach?

Welding precipitation-hardened aluminium alloys can significantly reduce material strength in the heat-affected zone.

Bolted connections avoid this particular problem, make individual components easier to replace, and allow assembly without specialised welding equipment.

However, this does not mean that a bolted structure is automatically better or safer.

Every hole, every gusset plate, and every bolt must be properly engineered. Particular attention must be paid to stress concentrations, material fatigue, and load transfer between structural members.

Engineering also means being willing to make changes.

A good example is our tailbooms.

During development, we revised their planned dimensions from Ø50 × 5 mm to Ø80 × 3.5 mm aluminium tubes.

The larger diameter provides substantially greater bending stiffness at a comparable weight per metre.

But that is only part of the equation. The revised tubes and their attachment points still require structural verification.

And that is precisely why these two tubes are not included in today's delivery.

What comes next?

Our next steps include finalising the structural joints, calculating the relevant loads, and preparing the components for manufacturing.

Only after appropriate verification will we proceed with assembly.

RSG Diamond is being developed around a simple belief:

Building your own aircraft should not be a privilege reserved exclusively for large companies and enormous budgets.

But making aviation more accessible must never mean compromising safety.

A simple structure does not mean simple engineering.

🚁 RSG Diamond — Built with purpose. Engineered with reason.

16/10/2026

# PHILOSOPHICAL FRIDAY

# # WHAT IF THE WORST THING THAT COULD HAPPEN TO A DREAMER IS... HAVING THEIR DREAM COME TRUE?

Imagine someone who decides one day to build their own aircraft. A plane. Or a gyroplane.

Not buy one ready-made.

Not order one from a factory.

**Build it themselves. From the very first sketch to the very last bolt.**

At first, there's nothing but an idea. A few drawings, some calculations, and a vision of a machine that doesn't yet exist.

Then come the months. Perhaps years.

Sleepless nights. Hundreds of decisions. Thousands of questions. Problems that nobody else is going to solve for them.

Sometimes things don't fit. Sometimes weeks of work have to be thrown away and started all over again. Sometimes there's not enough money, not enough time, or simply not enough energy.

And there are always people who ask:

*"Why go through all this trouble? Wouldn't it be easier to just buy one?"*

But there's something they don't understand.

**The goal isn't simply to own a machine that can fly. The journey of creating it is part of the dream itself.**

Every problem solved is a small victory.

Every completed component brings us closer to a moment that, for years, has existed only in our imagination.

Until finally, that day arrives.

The aircraft is standing on the runway.

The engine is running. The rotor is spinning up. The open sky lies ahead.

And then comes that extraordinary moment when the wheels leave the ground.

**We're flying.**

The dream that once seemed so distant has become reality.

It's hard to imagine a greater feeling of achievement.

But...

A week passes. A month. A year.

The first flight becomes a memory. The tenth no longer feels quite so extraordinary. By the hundredth, flying has become something almost natural.

The machine we once admired only on a computer screen is now sitting in a hangar. We can walk up to it, open the cockpit, take our seat, and fly whenever conditions allow.

What once seemed impossible has become part of everyday life.

And one day, perhaps during a peaceful flight over familiar landscapes, a strange thought appears:

**"Well... what now?"**

Have we finally reached the end of our journey?

Is the moment we fulfill a dream also the moment we lose something incredibly precious — the dream itself?

Or perhaps we've misunderstood what dreams are really about.

Maybe a dream was never just a destination.

Maybe it was the force that made us get out of bed every morning, learn new things, experiment, and try again when everything seemed to go wrong.

Maybe it was through that dream that we discovered skills, patience, and determination we never knew we possessed.

If that's true, then the first flight isn't the end of the story.

**It's simply the end of one chapter.**

Because the moment we fulfill one dream, there's nothing stopping another from being born.

Perhaps we'll want to fly farther.

Perhaps we'll build something even better.

Perhaps we'll help others — people who look up at the sky today and think, "That's not for someone like me" — discover that they, too, can find their way up there.

Or perhaps the next dream will be something completely different.

It doesn't matter.

What matters is that there is one.

At RSG Diamond, we're not simply building a gyroplane.

**We're building proof that an idea which once existed only in someone's imagination can one day lift off the ground.**

And perhaps that's why we shouldn't be afraid of our dreams coming true.

We should only be afraid of the day we stop creating new ones.

---

**Because perhaps the greatest tragedy isn't dying with an unfulfilled dream... but living without having anything left to dream about.**

And now, a question for all the dreamers, builders, and pilots out there:

**When you first took to the skies — or finally accomplished something that had seemed impossible for years — did you feel that you'd reached your destination?**

**Or was that the very moment you realized another journey was just beginning?**

*RSG Diamond Project*

11/10/2026

From the Builder's Log... 🛠️🚁

There are days when you look at your project and think, "Damn, this thing is actually starting to look like a gyroplane!"

And then Monday comes, you open Blender, and discover that one of your bulkheads has a split personality.

Actually, make that a triple personality. 🤣

Welcome to the world of building the RSG Diamond!

Over the past few days, we've been preparing the cabin geometry for CNC machining and converting our 3D models into STEP files.

Sounds boring?

Try convincing several dozen complex 3D solids that they need to be watertight, geometrically valid, and actually manufacturable — rather than just looking pretty on a computer screen.

The result? 41 STEP files successfully exported and imported back for verification!

Forty-one little victories over mathematics, software, and our own patience.

And then came the bulkhead.

One object in Blender. Three separate solid bodies. And a converter that apparently decided that since they all live under the same name, they must be one happy family.

Unfortunately, geometry doesn't recognize domestic partnerships between solids separated by 60 millimeters. 😂

Instead of hitting the "Ah, it'll probably be fine" button, we stopped the export and started investigating the problem.

Because there's one thing we definitely don't want to find out during the maiden flight:

Whether our design mistakes can fly as well as the Diamond.

Meanwhile, our 6082-T6 aluminium is on the final leg of its journey to our workshop.

And you know what?

After all those hours staring at a computer screen, the prospect of drilling holes, bolting the frame together, and finally holding real aircraft parts in our hands is starting to sound like a Caribbean vacation.

Although, knowing our luck, the very first hole will probably end up half a millimeter off. 🤣

But that's what building your own aircraft is all about.

Not pretending that everything goes perfectly.

It's about solving problems before the wheels ever leave the ground.

RSG Diamond. It doesn't fly yet. But it's already doing a fantastic job of raising our blood pressure. 🚁

09/10/2026

💎🚁 **FRIDAY AGAIN! OR HOW NOT TO LOSE YOUR MIND WHILE WAITING FOR ALUMINIUM.**

They say that as you get older, you become calmer, wiser, and more patient.

They say.

We have absolutely no idea who conducted that research, but we're pretty sure they didn't include people building their own gyroplane. 🤣

A normal person orders something and checks the delivery status once a day. A slightly impatient person checks twice.

We've reached the point where refreshing the tracking page should probably be included in our official construction schedule. 😂

And it's not like we're waiting for a jet engine, golden wings, or a suitcase full of money.

We're waiting for... aluminium profiles.

Yes. Ordinary pieces of metal.

To most people, they're just materials for a fence, a shelving unit, or perhaps a particularly ambitious clothes-drying rack.

To us, they're the future skeleton of the RSG Diamond.

And that's where the trouble begins, because **our imagination is running way ahead of the logistics.**

In our minds, Diamond is already standing on its landing gear, the engine is running, the rotor is spinning, and we're seriously considering whether to bring a camera or a spare pair of trousers for the first flight. 🤣

Meanwhile, reality gently reminds us that first we need to receive those profiles, assemble them, bolt everything together, check it, calculate it... and probably discover several times that there was a much simpler way to do something.

Our 6082-T6 aluminium has almost completed its grand European tour. If everything goes according to plan, we'll finally meet it in person next week.

We cannot rule out tears of joy.

We cannot rule out hugging the packages.

We would, however, strongly advise against mentioning any of this to your family doctor. 😂

But seriously, for a moment...

There's something truly amazing about knowing that those ordinary pieces of aluminium, currently sitting somewhere in a logistics warehouse, could one day become part of a machine that lifts a human being into the sky.

And perhaps that's exactly why it's worth being just a little bit crazy.

**Have a wonderful Friday, friends!**

And if you ever happen to see a man staring dreamily at an aluminium profile with a big smile on his face...

Don't disturb him.

**He's already flying.** 💎🚁

---

And if you're curious to see how a bunch of ordinary aluminium profiles slowly turns into a real gyroplane, **stick around and follow our journey.**

The most exciting chapters of the RSG Diamond story are still ahead of us. 😉

07/10/2026

The final stopover for our 6082-T6 aluminium.
Next week, it’ll finally be with us. :D

04/10/2026

FROM THE BUILDER’S LOG
Sometimes progress looks like an aircraft.
And sometimes it looks like fixing half a millimetre of foam. 😁
This week, we’ve been working on one of those parts of building the RSG Diamond that rarely makes it into spectacular videos — turning the cabin geometry from a 3D model into real parts that can actually be manufactured.
Our original plan was to use PUR foam. Discussions with the CNC manufacturer quickly challenged some of our assumptions. Some shapes proved too fragile, certain bevels simply cannot be reached by the cutter, and PUR itself turned out to be more brittle than we would like for this application.
So we are now adapting the cabin components for PET foam.
Sounds like a simple material change.
It isn’t. 😁
Every part has to be checked again: thickness, contact surfaces, bevels, intersections, CNC tool access and, most importantly, whether something that looks perfect on a computer screen can actually become a physical part.
A few times already, the answer has basically been:
“No. The machine simply can’t make that.”
So... back to the model we go. 😁
It isn’t the most spectacular part of building an aircraft. There’s no engine start, no spinning rotor and certainly no first flight.
But this is exactly where a prototype slowly stops being a collection of ideas and 3D models and starts becoming something that can actually be built.
One part at a time.
RSG Diamond — From the Builder’s Log
Different problems. Same goal: make it real.

29/09/2026

🔧 TECHNICAL TUESDAY — The rotor doesn’t just lift the aircraft. It designs the frame.
Looking at a gyroplane rotor, it is easy to think of it simply as the part that generates the force needed to fly.
From a structural point of view, however, things get much more interesting.
For the RSG Diamond, we plan to use a two-bladed Gyro-Tech rotor with a diameter of 8.4 m, using composite blades with a NACA 8H12 profile. In normal flight, we expect it to operate at approximately 300–330 RPM.
But the Diamond’s frame does not simply have to carry the weight of the aircraft “hanging” from the rotor.
Through the rotor head and mast, the structure must also deal with loads resulting from rotor drag, manoeuvres, changes in rotor-disc orientation and dynamic loading.
That is why, before we begin the detailed structural calculations of the frame, we need to define as accurately as possible the load cases that the structure must safely withstand.
Recently, we received from Gyro-Tech the reports from static strength tests of the rotor blades and their connection to the hub bar. These are valuable data for us, although there is still considerable work ahead in defining the loads acting through the complete rotor–head–mast–airframe system.
The vectors shown in the graphic are schematic and not to scale. They illustrate the types of forces and moments involved and how loads are transferred into the structure — they are not the results of our final structural calculations.
It is also a good example of how aircraft design works in practice.
A change to one component at the very top of the aircraft can influence the design of structures much further below.
The rotor may be above the aircraft.
But structurally, its influence reaches all the way down to the landing gear.
🔧 RSG Diamond — engineering in progress.

25/09/2026

FRIDAY PHILOSOPHY
WHEN IS A DESIGN READY TO BE BUILT?
When the 3D model looks perfect?
When every part fits together on the screen?
When there are no more changes to make?
Or maybe… never?
Anyone who has ever designed and built something from scratch probably knows this moment.
There is always something else you can improve.
Run another calculation.
Move a hole a few millimetres.
Change the material.
Refine the geometry.
Make another version.
And every one of those changes may genuinely make the design better.
But at some point, another question appears:
Are we still designing so that we can build the prototype — or are we postponing the prototype so that we can keep designing?
Because a prototype has one very important feature.
It doesn't know how many hours we've spent in front of a computer.
It doesn't care how beautiful the CAD model looks.
It simply shows us where we were right…
and where reality had a different opinion. 😉
Of course, in aviation this does not mean: “stop calculating and just build it.” Quite the opposite. The structure has to be carefully considered, calculated and safe.
But even the best analysis doesn't change the fact that the first prototype is also part of the design process.
So where is the line?
When does careful engineering become endless engineering?
And how do you know when it's finally time to close the CAD… and start cutting metal?
RSG DIAMOND — engineering in progress.

22/09/2026

PHILOSOPHICAL TUESDAY

How do you prepare a gyroplane for winter?

The procedure is simple, although slightly time-consuming.

We start with the landing gear.

Tyres — studded, obviously.
There is really nothing to discuss here. Traction is important.

Especially in the air.

The rotor? Of course.
Nothing can be neglected here either.

First, carefully coat the rotor blades with bat fat. Then wrap them in baking paper to prevent ice from sticking to the surface.

Snow chains are optional, but highly recommended in wet snow or hail.

Next comes one of the most important steps of the entire winter preparation:

Put a condom on the Pitot tube.

Yes. The Pitot tube.

Not the pilot.

Although it probably wouldn't hurt the pilot either.

We all know what can happen when the little hole in the tube freezes.

Better safe than sorry.

Finally, we have the pusher propeller.

It also needs proper protection against low temperatures, wet snow and winter conditions.

After extensive testing, we have found that insulated rubber boots or ordinary wellingtons provide the best results.

With a two-bladed propeller, the procedure is straightforward:

left boot — left blade,
right boot — right blade.

The real engineering problem begins with a three-bladed propeller.

Because...

where the hell do you buy a left, a right and a middle boot?

With four blades, theoretically, you can simply buy two pairs.

Unfortunately, that leaves you with two left boots and two right boots, and the propeller manufacturer's manual remains suspiciously silent on the subject.

Therefore, before the winter season begins, we strongly recommend reconsidering your propulsion configuration.

Safety first.

RSG Diamond
Engineering in progress. 😁

20/09/2026

From the Designer’s Log

HOW MANY FILE FORMATS DOES IT TAKE TO BUILD A GYROPLANE? 😁

Apparently, the answer is:

more than anyone should ever have to learn in one lifetime.

While designing the RSG Diamond, we finally reached the point where we had to turn a nice-looking 3D model into something considerably less romantic:

parts that can actually be manufactured.

First came the DXF files.

They looked good.
The files opened.
The names matched.

Success?

Not quite. 😂

It turned out that, from the manufacturer's point of view, our beautiful 3D parts were…

flat as pancakes.

All right.

DXF goes aside.
We move to STEP.

Export everything again.

And surely, this time everything will work.

Of course not. 😂

The CNC guys looked at our models and found:

– tiny teeth,
– little steps and discontinuities,
– bevels the milling machine simply couldn't reach,
– parts that were supposed to be flat plates but apparently had other plans,
– and long pointed sections that very quickly earned the working name “antennas.”

Meanwhile, we carried out a material test with PUR foam.

PUR + laminate + demoulding.

CRUNCH.

Thank you, PUR, for your participation in the project. 😁

So PUR is being replaced by PET foam — less brittle, thermoformable, and much better suited to what we're trying to achieve.

Which means:

New material.

Another model revision.

Another export.

More STEP files.

Another CNC analysis.

And another collection of places where the computer says:

“Yes. This geometry exists.”

while the person standing next to the milling machine says:

“Yeah… but there is no damn way we're making that.” 😂

And that's exactly why working with a company that actually analyses the models before production is so valuable.

Every tooth, step, impossible bevel or “antenna” discovered now is one less problem to discover when the material is already sitting on the CNC table and starts costing real money.

Designing a prototype isn't really:

idea → computer → finished part.

It's more like:

idea → model → export → manufacturer → “can't make that” → dictionary of inappropriate language → revision → export → “can't make that either” → extended dictionary of inappropriate language → revision → coffee → export → SUCCESS → wild celebration → discover the next problem. 😁

But that's how a real machine is created.

Not by pretending everything worked perfectly on the first attempt.

But by finding the problems before they become expensive problems.

RSG Diamond — for now, it's being built mostly from aluminium, PET foam, STEP files, coffee, patience and words generally considered unsuitable for polite conversation.

But it is being built. 😂

RSG Diamond — engineering in progress.

RSG GyroFly

20/10/2026

16/10/2026

11/10/2026

09/10/2026

07/10/2026

04/10/2026

29/09/2026

25/09/2026

22/09/2026

20/09/2026

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