Tag Archives: heli

EXI-450 Helicopter — Build Day 2

Spent a couple more hours working on the 450 last night. It’s coming along nicely. Today I didn’t need to grind anything.

A couple of the many tasks required to get this thing in the air, is balancing the main blades and applying Loctite to all metal to metal fasteners. To accomplish this I needed some very small metric hardware and a new tube of low-power Loctite. A lot of people are using Blue Loctite 242.

Loctite 222MS 'Purple' thread locker.

I don’t think it’s the proper compound for fasteners of the size we’re using, so purchased a large bottle (all they carried at the store) of the Purple Loctite 222.

The place I like to go for such things is Tacoma Screw (there is one local in my town, about 35 miles from Tacoma itself – for this I’m glad). It’s a jobber style shop with top-notch customer service, curious people behind the counter (by that I mean they like to talk about what you are working on) and always friendly. I picked up a pair of German Philips #0 and #00 screwdrivers:

A pair of good German screwdrivers.

Also picked up 100 2mm washers:

Pack of 2mm washers. Always good to have some washers on hand. This case $1.50

And finally, a long 2.5mm bolt and nylocks for making a home-brew pour-boy blade balancing rig:

Cheap balancing rig. Less than $1.00 in fasteners and an old vice.

I ran one of the nylock nuts down on the screw, about 2/3 of the way. Placed the blades on the bolt and ran down the other nut, just making them snug. I chose the nylock nuts because I knew that they would stay put once I achieved the snugness wanted. A few extra pennies spent to save a lot of potential frustration later. You learn these sorts of things being a gearhead for nearly 4 decades.

Close-up of the balancing operation. This worked very well!

The frame on the EXI-450 Plastic V2 is made of a stamped metal (you know, I think it’s aluminum, but I’ve not confirmed that), so some of the edges are rather sharp. To prevent the cutting/chaffing of wires where they exit the frame, I placed a small bit of high-strength tape (red) on the frame and then places a heavy duty heat shrink tubing over the wire bundle and applied heat to shrink with a heat gun, which works orders better than a lighter. You can get a cheap heat gun at Chinese places like Harbor Freight for around $10.

Heat shrink tubing applies to servo wires near body exit.

Here is the reciever I plan to use for this helicopter. It came with the Spektrum DX6i transmitter I purchased last month, and have been using with the ParkZone P-51 and Blade CX3. Not in this photo is the 2nd remote antenna/receiver that provides a very long range capability.

Spektrum AR6200 receiver I plan to use in this build.

Installing the linkage balls on servo horns was next. The idea here is to make sure the link bars are as perfectly vertical as possible when installed on the servo, so some trail and error is required to select the correct hole to mount the balls. In this case both of the forward servos were able to use the last hole. You’ll notice that the balls are mounted in ‘reverse’ so the ball is on the servo’s side of the arm. Once they are all installed and photos taken, the reason for this will be clear.

Setting up the servo horns and linkage balls.

Unfortunately, not all servo placements allow for such cut-and-dried installations. To get as close to pure vertical actuator alignment, you sometimes have to get a little fancy with the servo hardware. Once again, out comes the cheap Harbor Freight heat gun to apply some ‘persuasion’ to the nylon horn. After determining how much offset I needed, it was made very hot and then adjusted.

Having to get a little creative for the pitch swash servo horn.

I think this makes it a little clearer why the adjustment was made and how it all turned out. This is the pitch cyclic primary servo.

Modified horn test fitted in frame.

The fly bar on a Bell-Hiller head is critical to smooth and stable flight. To get the fly bar properly setup, the first thing that has to be done is make sure it’s absolutely centered. Measuring with a caliper seems like a pretty accurate method.

The flybar must be perfectly centered in the rotor head, so measure twice, move once is the mantra.

Larger photo of the Bell-Hiller rotor head, typical to R/C helicopters.

Bell-Hiller rotor head, with flybar (forground). Main blades not installed.

Unlike yesterday, I placed the ‘calling it quits for the day’ photo at the end of this post.

Progress report - End of Day 2. Looking a little more like a helicopter.

It’s looking a lot more like a helicopter now! I still need to get some important things before I can go much further, the most critical of which is my batteries! I think I mentioned it in the last post, being unable to source a suitable battery at the local hobby shop, soooooooooooo yet another package of stuff is on the way. I’m sure I could have save $30-40 on shipping if I’d spec’d out my needs better ahead of time. For someone that is such a stickler for planning, I didn’t do a very good job of it for this project so far! :p

MORE PARTS! Along with 3 450 class batteries, I'm getting a good charger!

Sometimes it seems you can’t catch up. More Madhawk300 frustration.

So, the replacement blades are just about here for the MadHawk300 FP heli. Awesome. Except, yesterday the dang thing flipped out, suddenly went to full throttle while I was getting ready to swap out the batteries.

It did the ‘Chicken Dance’ on the park bench, snapping off parts the tail rotor. Radio throttle response did not help, it idled down and was just sitting there vibrating wildly (due to broken tail rotor). Carefully reaching under I unplugged the battery.

Swapped the new battery in, got the TX and RX talking to each other… but what now? No throttle!

So, I now have two shattered main blades (replacements arriving today), broken tail rotor ($4.00 which I’d have to mail-order) and now.. neither motor is spooling up!

On the workbench this morning I checked the motors and radio. Seems the RX is no longer sending voltage signals to the motors. Great… why did it do that? Well, a good 6 channel DSM2 receives is about $35 so I checked on the price to replace this thing.

WTH?? Really? $50?!?!

ExceedRC RX2423 replacement cost.

Oh come on now! Worth $15, maybe. Ugh.. more parts. At this point I’m chasing my tail on this thing. It was only $100 new, and 1/2 of the price for the receiver? Might as well just buy a new one and use this for parts! Honestly, I liked the way it few, it was fun, docile and a good trainer, even if the range was HORRIBLE, which I thought maybe I’d fixed by moving the receiver further from motor.. but.. it freaked out and crashed before I could range test.

I’ve read many people doing upgrades to make the thing really reliable. Sounds interesting for certain! But.. then, why toss more good money after bad? Shouldn’t I just chalk this up to some good training and park the thing?

I mean.. for the price of the MadHawk300 I could have bought a EXI-450 AND TX/RX for about the same price!

Then I could get replacement parts locally. Now.. the above also needs:
– motor
– rotor blades
– ESC (electronic speed control)
– Li-Po battery

But it’s also easily upgradable.. with stuff like this, a full CNC rotor head and tail, plus some spare blades:

Or, as my final plan for the EXI-450 I’m waiting for, a scale rotor head:

Sweet 4-blade flybarless scale rotor head.

Update: 9-June-2010 — EXI-450 is here!

And of course you can get really nice scale bodies very inexpensively for the 450’s, especially when compared to the proprietary bodies for other cheaper birds. Here is a short like from just one online retailer:

Factor in cheap proprietary electronics, motors that notoriously fail (tail motors) parts that are not available in any local store, batteries that are a strange size… and you have an exercise in frustration as soon as you run into a snag. And even if you are an expert flyer, you’ll run into a mechanical failure, or electronic failure and voila.. the questions about WTF have you done begin.

So, I’m really REALLY looking foward to the arrival of the EXI-450 kit this week. I’m really bummed that I have nothing to fly right now. 🙁 But at least with the 450 if I break something I *can* get a local replacement part!

Conclusion:
Would I buy a MadHawk300 or Walkera 180x bird again. NO!. I was warned about quality early on, and I chose to ignore that advice of one vocal expert, compared to the many voices singing it’s praises. Well, guess who was right?

Will I fix it at some point? Maybe. But certainly NOT with factory parts. I might turn it into a learning experiment to see what I *can* do with it. But… to what end? I don’t know. The $$$ is better spent on a 450 or 600 class bird instead of patching together what is not basically an expensive paper weight.

Upside, if there is one, is that the radio that came with it might be able to be used as a simulator controller with a $10 cable. 🙂 Maybe I’ll pick one up on the way to work and see what happens.

Blade CX3 nearly meets it’s demise – out of action

Yesterday evening, was a great evening to fly. Not much wind, very very light rain and nobody at the ‘fly zone’ to accidentally kill. When you are unleashing an 8 year old piloting a P-51 Mustang model, these are things you need to consider. To be honest, he’s better at flying it than I am.

While the P-51 was zooming around the park, sometimes slamming into the ground nose first at full throttle (foamy planes are really good trainers) I took up the two Helis for some practice.

First up was the MadHawk300. The CX3 and Foamy P-51 are both bound to the same transmitter, so I could not fly the CX3 while the transmitter was in use. I’d done some tuning on it, adjusting the motor. The last failed flight attempt was dashed when on run-up the main pinion began to slip at 1/2 throttle, keeping the heli from getting off the ground. I’ve since lock-tited those motor motor screws.

It few well. Adjustments I made to the swash gave me some really nice control. At higher speed and throttle, helicopter flight dynamics are not at all intutive to a guy that’s used to fixed-wing models. But it still went well, with a couple of hard landings, no big deal.

Then, it happened. While at the east end of the part, close to one of the Pavilion buildings, the tail suddenly started to swing wildly, it accelerated upward, then nosed rolled right and slamed into the pavement at near full throttle, doing quite a number of the landing gear and main rotor blades.

Madhawk 300 with broken landing skid.

🙁 Nothing that was too tough to repair, but I didn’t have the wrench to replace the rotors on site.
Toasted main rotor blade on the Madhawk 300.

At this point the battery on the P-51 was running low. I recouped the transmitter and started to fly the CX3. It was flying very nicely. Nicer than the Madhawk in fact! Zoomed round the park, turned on and off the model navigation lights, did some high speed passes, landings, just some fun landing.

Then, it happened.

Right in the same place the MadHawk had trouble, the CX3 started to go crazy, and started to go into the TBE death spin. I tried to regain control but no luck. It accellerated upward, then nosed over and went straight down, nose first into the ground at full throttle. 15′ was more than enough room for it to gain some momentum.

CRUNCH. It was not a nice scene. The following photos are after I attempted a field repair on the fusalage to fly again. Unfortunately it would not happen since the radio and transceiver were no longer talking to each other.

Once home, I tore down the heli (I’m getting far too good at this) and discovered that the radio receiver took the full-force of the crash. Part of it’s case was ripped off and one of the dipole antennas was missing. Oh oh!

Helicopter on the operating table. Trying to get TX and RX to talk to each other

Removed the plugs from the Spektrum AR6100e receiver in the heli, plugged in the 3-in-1 mixer, checked response. The mixer would not show it’s green ‘lock’ signal. It was not until later that I noticed that the signal lock LED on the AR6100e’s front was actually missing. But it was at that point I realized, that not only was the body smashed, the lower section of the frame mounts for the battery are broken, but the receiver is, completely, shot. I’ve broken at lot of things crashing R/C aircraft, but never destroyed a receiver. It’s at this point I’m thankful for using Spektrum R/C equipment. Replacements are 1/2 that of Futaba or JR radios. Still, it’s a $55 part. Ugh. 🙁

Close up of AR6100e broken receiver (unmounted) and 3-function mixer (mounted)

I don’t want to order a replacement receiver unless I *know* that’s what is broken. So I dug up the AR56200 full-range receiver I have, wired it in to the heli’s remains, and tested. Viola. 3-in-1 mixer lock and receiver lock. It’s a go. Now I just need to decided where, and when, to buy a new receiver. In the mean time, she’s out of commission.

At least I still have the MadHawk300 to fly. And if I crash that into pieces, well.. I’ll just say I have a contingency plan arriving for that soon as well. ):

What's next!?!

Digging this MD500E Scale Helicopte vid

Found this on the XHeli.com Facebook page. Love the sound of these things.

I’m anxiously awaiting the arrival of my EXI-450 from XHeli.com, hopefully in the next week! Then I’ll have to build it. Then learn to fly it. Then learn how to repair it after I crash. Eventually I want to add a body kit like this, and replace the stock plastic parts (ordered plastic on purpose, about 1/2 cost and I plan to replace it as noted) with one of these:

HAC 4 blade Rotorhead for 450 class Heli

CX3 repaired and flying again!

The Blade CX3 is repaired and flying again! The $22 aluminum swash plate repair, actually has the thing flying better than it did right out of the box!

E-Flight OEM Plastic Swashplate E-Flight Upgrade Aluminum Swashplate

Here is a 3 min video of first test flights in the studio, and finally my 8 year old attempting to fly it, for the first time, outside! The crosswind was playing havoc but he did a pretty good job of keeping things together. I think he’s going to be a good pilot some day.

Even though it’s a Toy Co-Axial helicopter (a $200 “toy” to be exact), with the upgraded part, it’s a joy to fly. There is something so therapeutic about an activity that puts nice big genuine smile on your face. And in the end, what price is too high a price to pay for some joy? 🙂 Even though I’ve “outgrown” this helicopter in about 1 week of intense practice, I still want to keep it around, and even put some more upgrades on it! Such as this cool LED strobe kit I’ve seen on the web. Here is a video from a guy that I think, sells the best of them:

Here are a few pics flying it outside, just before dark. Shot with an f2.8 200mm lens, 50D camera set at ISO1600 and roughly 1/30th second shutter speed. Despite the slow speed and high ISO, I think the shots are work posting.

Blade CX3 spooled up and ready for takeoff.

Blade CX3 spooled up and moving out. Still in ground effect.
Blade CX3 after battery change, ready to go again.
Blade CX3 in flight.
Blade CX3 flies overhead.

More pics of AirLift Northwest EC-135 N953AL

It’s been months since I have seen this bird at Harrisons. It’s a great looking example of the EC-135 Eurocopter.

I’d more recently seen another EC-135, but it had much different livery, but still flew with the AirLift Northwest logo:

EC-135 N139AM

Here are a few of the photos I took today:

AirLift Northwest EC-135 N953AL starts takeoff.

AirLift Northwest EC-135 N953AL starts takeoff.
AirLift Northwest EC-135 N953AL clears the hospital helipad.
AirLift Northwest EC-135 N953AL climb-out.
AirLift Northwest EC-135 departs South-East.

I also have video shot with my old Canon DV camcorder (found it in a storage box yesterday). Right now I don’t have the right Firewire cable for my MAC. Hope to get that resolved tomorrow.

Maximum Geek-out. R/C + iMovie = ???

It was bound to happen, taking the next step and actually taking 2 minutes to edit my little ‘movies’ (really a personal video diary of my learning to fly and crash little flying machines). Here are the first two that I actually was able to load into iMovie and convert.

First is the Revel Proto CX. My micro counter-rotating blade heli: I cut a bunch of worthless time (more worthless that this video, hard to image but true) out of the middle and focused on the ‘good stuff’:

Next is video of the bird #2, the Blade CX3.

EFlite Blade CX3 - MD520 Notar

I had just unpacked it, installed the training gear extensions (the funny orange balls) and bound it to the Spectrum radio that came in the ParkFlyer HobbyZone P-51 foamy. That was a nice little treat.

Blade CX3 - MD520 Notar

For the most part it worked great. Here 90% condensation of about 25 minutes of actual flight time with the CX3. This was my first attempt.

However, yet again, I managed to mangle the landing gear after a few panic throttle chops as it got a little close to big steel things that would break it. :/ Back to the hobby shop for MORE stuff!

Blade CX3 replacement landing gear. I left them 1 on the rack. At least they are not TOO expensive!

And finally, here is my repair video. First semi-successful attempt at time-lapse with the Canon S1100 micro-camera. The hardest part, I thought, would be learning how to do this with iMovie ’09. Nope, after some prodding around it turned out to be pretty simple. Sadly the camera was doing some sort of zoom-in and zoom-out madness. Site down before watching, you might get ill. Some are going to wonder about the music. Did I shot the video with this music in mind. NOT! Who’d try to shoot video like this, outside the brain-dead corridors of intellectual bankruptcy one finds in L.A. or N.Y.? No, but the frantic into to a good German industrial metal song just… WORKED! I only hope YouTube does not over-dub the music with something totally lame out of their music library, as I’ve heard they have started to do this.

UPDATE!

YouTube send me this message today. Hopefully they don’t over-dub the music. But, when you’re using a free service, their hardware, their network, it’s not a stretch to concede they own that copy of it.:

Your video, Eflite Blade CX3 MD520N (Notar), may have content that is owned or licensed by UMG.

No action is required on your part; however, if you are interested in learning how this affects your video, please visit the Content ID Matches section of your account for more information.

Fleet is expanding (heli 3 and heli 4)

It’s beyond obsession at this point. I’m going to need a 12-step program.

Yesterday I converted some old ‘iron’ at the gun shop to one of these at the hobby shop (I don’t have a need for a piddly 9mm anyway). This is Heli #3:

Blade CX3

As I type, the batteries are charging for the Heli, and the transmitter.
Blade CX3 battery packs and DX6i transmitter charging up.

I saved $35 by buying the BNF (Bind-n-Fly) version of the kit. The Spektrum DX6i I already obtained is compatible with this (and the P-51 too as a matter of fact).

Then this morning, I received shipping confirmation of ‘Heli 4’ from the on-line retailer XHeli.com. This is my first time ordering stuff from them. What surprised me was that within 24 hours the merchandise was picked, packed and on it’s way!

Thank you for shopping at XHeli!
Your order’s shipping label is generated and is scheduled
to be shipped on 05/21/2010 via UPS.

EXCELLENT!!

New Heli and parts on the way!

I’m having it shopped to my office in Tacoma since I don’t want to have it sitting on my porch all day at work. Plus, there is ALWAYS someone there to sign for it, since we are 24×7 shop. Fast FAST shipping and great prices. We’ll see how it all works out.

This is what I’m expecting. 🙂

Exceed MadHawk 300

ESky Flight Training System

Now, I already had this one here. Which now I think I paid WAYYYYYYYY too much for:

RealFlight Basic

I’ve been practicing with it for a week now. It’s OK, and it has some cool planes in it, but the helicopter physics seem… weird. Really weird. And I completely irritated that I had to build a WINDOZE box to use the thing! Luckly I still had an old (circa 2006) Dell computer floating around, and it’s running Windoze XP (which the new software needs too.. got lucky there), but the hardware was not up to the task. Wish I’d known that when I bought it. So $100 for the software kit, then I had to toss in another $80 to get a decent DX9 compatible video card for the OLD PCI (not enhanced regular old PCI) interface, AND 1GB of memory for another $50. (poor thing only had 128MB in it.. not enough to even open the program.
So almost $250 to construct a flight simulator with a used computer!

Then.. then, I find this recommendation lurking around one of the Heli message boards. Heli-X.

It’s written in Germany AND it runs on Mac OSX!!!! So of course I downloaded it (it does not come with any controller, BUT the controller from RealFlight works PERFECTLY!). It’s also fairly pricey too at $50 Euro, and it only handles Helis BUT the physics in the trainer are SO much more realistic, at least to me.

Here is a shot of the simulator (sorry, I don’t have the controller hooked up at the moment so it’s just a shot of one model on the ground). It’s pretty good, and I’m learning that Variable Pitch, fixed throttle flying IS A LOT more intimidating that fixed pitch variable throttle!

Screen Shot of Heli-X

When will this end?

Proto CX Heli Flies Again (for a moment)

After a number of pretty bad nose-in crashes (flying nose in is the most challenging), the bird was getting pretty beat up:

Proto CX crash worn

With the landing gear broken and the canopy smashed, it was looking very ragged. Not only that, but the metal rod and zip ties I had holding the landing skids together added enough weight to make it fly a little funny (balance, what balance?).

Removing the weight of the rod, well.. that was not really an option:

Broken and beaten Proto CX

Fortunately, the local hobby shop has a variety of replacement parts for these things (big shock, isn’t it?). The landing gear itself was about $8.50 to purchase. Easy enough. However, with all the plug-and-play miniaturization on these things, one thing that was not plug and play was the landing gear + battery tray. I’d have to perform some micro soldering to complete the repair.

Replacement landing gear for the Proto CX

I lit up the soldering iron and did my best. Turns out that it was a little easier than I thought it would be. Plus, I didn’t accidentally melt any of the sensitive parts, like that servo there, located perilously close to the solder points I needed to use.

Completing the repair.

With the important structural stuff fixed, the canopy was re-attached and she’s ready to fly. Good, maybe bad, but the shop did not have replacement canopy in stock. It’s OK I suppose, since I’d crashed this many times on the nose before the canopy finally shattered.

Broken gear left, repaired bird right.

Some pieces are still missing, but some clear tape and Sharpie marker returned it to serviceable condition. It’s not going to win a beauty contest, but it does fly, as you can see here!

Learning to Fly… R/C Helicopters

Learning to Fly……… Radio Control.

Actually, it’s more like re-learning how to fly Radio Control. In my formative years, I had a number of Radio Control cars, planes and gliders. All of them fun in their own exciting ways. One thing I’d always heard over the years, was how difficult and expensive it was to learn to fly an R/C helicopter. Which is, of course, why I’m trying to do it. I love a challenge.

Research shows that keeping the brain (and body) learning new things is the best way to combat age-related maladies of the brain. Having relied on my brain to get great jobs, and even a few times, it’s come in handing finding clever ways to get out of life threatening dangers including things from terrible car crashes to being assaulted at gunpoint. So, my brain is a pretty important thing to me. Fortunately, my work challenges me on a daily basis. I once tried to explain why I sometimes looked so tired after a long day’s work. I’d tell people to imagine taking the semester final exam in the toughest class you’ve every taken, and then do that every day, 5-days a week, 50 weeks a year.

Sure it’s challenging, but really, I’d like to find some fun ways to keep my brain active besides work. So, I’ve giving R/C helicopters a try. They have some a long way since my last adventures in R/C, some 30 years ago. They have come A LONG way. With the advances in electronics, some of the things that made R/C heli flying so dang near impossible for the mortal, are now handled via gyros and ultra-fast response servos, coupled to ultra-light weight electrical systems. Sure you can still buy big 600 and 700 class ‘gassers’, but you can buy the same big birds with high performance electric motors that never need to be tuned up, can be programmed to have very manageable torque curves, nearly infinite and repeatable power settings and of course, a lot less smoke and noise.

That said, flying a modern R/C heli is still NOT easy by any stretch of the imagination! I’ve talked to a variety of people flying them, and the advice has all been the same. Start out SMALL, with one of those indoor CR (counter-rotating blade) models. But get a decent one with a 2.4GHz radio that won’t cause you frustration due to horrible quality.

One specific model kept coming up while talking to people, the Revel Proto CX Helicopter. So I picked one up last week:

How did I get here? Well, there is, of course, a story.

It started early last month on a trip to California with my kids. While shopping at one of those California Super Malls for LEGO, The Boy was distracted by a pair of guys flying little model R/C helicopters around in the mall. He was transfixed. And really, I found it really cool too. We returned to the LEGO store.

I have a system when at the LEGO store with the kids. They have a budget to work within. If they want something in the budget, they can pick it off the shelf and we’re done. But, if it’s more than their individual budget they can lobby the other sibling to pool capitol and purchase more advanced kits.

Sometimes this happen, some times it does not. This time around it did not. In the end, he wanted a LEGO watch (of which they were out of stock). The Girl found what she wanted and we took care of that right away. Upon exit from the store, I was again urged to ‘check out’ the helicopters. I could tell he really REALLY wanted one, and with a birthday only a few weeks ahead, I caved. $40 later we were out of the mall with a bag of LEGOs and a tiny helicopter.

We attempted to fly it outside in front of my sister’s house. It was impossible. It was a windy day, and it was our first time. The helicopter spent A LOT of time spinning out of control and crashing into the ground. It was not long before all the landing gear was busted off and the once smooth rotor blades looked more like steak knives.

Upon returning home in Washington, we flew it inside the house, and much to our enjoyment, found that it flies pretty good when it’s not being subjected to wind! But it was still pretty beat up, flyable but beat up. And I can’t blame The Boy for not taking care of his new toy, I had just as much to do with busted it up as he did, if not more so. And this is how it all began.

I did not replace it right away. Those things are pricey. And I wanted to get one that would suffer a little more abuse with a little more dignity. A trip to the local hobby shop, talking to people online and in person, and a few days later I laid down some $$$ for a little trainer (the Proto CX).

Now, it’s become an addiction of sorts. Flying it all hours of the night, the television has not sat this quiet in quite some time. And that’s a good thing.

Now, today I finally found a suitable replacement for his first heli. It looks like a cool little sport kit, lots of flashing lights and some pretty sturdy landing gear. So now we have three of these little things in the house. Sometimes it’s like a little air show in the living room with little aircraft buzzing around everywhere. Pets seem pretty indifferent, which is fine with me. Less chance of one being stalked and pounced on.

So another adventure begins. Here is a really lame video of my flying this afternoon.

And finally, a neat video from a guy that actually knows how to build and fly these things. As noted in the video, the next step I was advised to take as getting a fixed-pitch heli and nailing down the general skills of multi-channel flight.