Tag Archives: helicopter

American Heros Day – Boeing Museum of Flight

What a fantastic Day at Boeing’s Museum of Flight. It was American Heroes Air Show at the museum. A day dedicated to the men and women that keep America safe by protecting our borders, fighting crime, rescuing us when we are lost or in peril, and saving lives when immediate medical care is required.

The morning started out very slowly. With less than ideal weather over Boeing Field, but the people still arrived early (before 7:00 AM) to watch and photograph the helicopters as they arrived. All were scheduled to arrive between 7:30 and 10:00 AM. Breakwater Insurance was on hand to provide complementary coffee, hot chocolate and muffins for the small crowd that had arrived 3 hours before the museum opened, to watch these wonderful aircraft arrive. They remained outside, in the weather serving the crowd late into the morning. That was appreciated.

We’d heard one helicopter transit the airfield above the clouds, so there was a brief bit of excitement, but after 10 minutes, we didn’t hear it any longer, and it was gone. People didn’t give up though, and at 8:30 AM, the thrilling arrival of the first helicopter via air (A King-5 news helicopter arrived before hand, on a trailer…. much to the crowds disappointment!).

First to arrive was the US Coast Guard in their short-range rescue helicopter, the Aérospatiale HH-65A Dolphin.

USCG - Aérospatiale HH-65A 'Dolphin'

They made a quick approach down the main runway, and then landed just outside the tarmac gates for the museum.

USCG - Aérospatiale HH-65A 'Dolphin'
USCG - Aérospatiale HH-65A 'Dolphin'

Not more than 10 minutes later, the second USCG helicopter arrived to the field:

USCG - Sikorsky HH-60J 'Jayhawk'

To say that it arrived with a lot more flare than the other helicopters that morning, would not be an overstatement.

USCG - Sikorsky HH-60J 'Jayhawk'

Once it had established over, the leading blades were creating just the right disturbance in the air, to create these contrails. And I’m pretty sure they were NOT splaying chemicals or conducting other experiments upon us with the contrails (that’s a contrail folks, not one of those mythical chemtrails). Unfortunately, I did not get any photos with the contrail in shark focus. :/

USCG - Sikorsky HH-60J 'Jayhawk'

Not long after the HH-60J was shut down on the taxiway, a Eurocopter AS350 arrived, and was directed to the landing area.

LEO - Eurocopter AS 350 B2

By now it was 8:35 AM, and the private museum members only presentation of the newly restored HH-52 USCG helicopter in the museum was about to begin, so AJ and myself hurried into the museum for the 1 hour talk about the history of the HH-52 (the USCG website has a writeup about this dedication).

Rear Adm. Gary T. Blore, Commander of the 13th Coast Guard District and current Ancient Albatross gave an excellent presentation of the helicopter, and related his own stories flying these historical life saving machines for the USCG. It held even the attention of a 9 year old body for the entire hour. If you wonder what the designation “Ancient Albatross” means, in short, it means he is the oldest active duty aviator in the USCG at this time (he’s retiring this summer, and the title will be passed to the next eldest in the fleet).

USCG HH-52 Seaguard

Among the stories and facts relayed. We learned;

  • the HH-52 is credited with over 15,000 lives saved
  • it has a boat hull that allowed them to land on water to recover survivors (a technique that is no longer used, because it was really quite dangerous)
  • Adm. Blore had to ditch ad HH-52 on his first mission into the Atlantic, at night, due to bird strikes that disabled the engine and severely damaged the main rotors
  • that Boston Whalers seemed be involved in an awful lot of rescues
  • they had a very limited carry capacity, despite the size, due to single motor being down-rated for cost-cutting measures (re-using existing hardware for the transmissions), sometimes only being able to pull 2 survivors at a time out of the water
  • off-shore navigation before off-shore LORAN and GPS was via dead-reckoning and that is quite difficult. Often they arrived back to the coast with very little fuel and far from an airfield, so they would land on the beach and call for a fuel truck

During the talk, several more helicopters arrived to the field. One of which was this US NAVY Rescure Hawk:

US NAVY HH-60H Rescue Hawk

With the museum opening to the general public in less than 1/2 and hour, and the new arrivals to the static displays, we hustled outside to see take it all in.

One of the first birds out was the Airlift Northwest Agusta. I see this helio a couple of times per week, landing across the street, but I still love to see these thing fly.

While talking to the pilot, I learned some interesting things about this specific helio, such as it’s complex auto-pilot allows them to fly in IRF conditions with just a single pilot. In fact, it does not even have a control stick in the left front. The only person with any controls is the pilot. And like he said, everyone on board is counting on him to be healthy during the flight.

Airlift Northwest - Agusta 109A
Airlift Northwest - Agusta 109A

Just like it’s arrival, the departure of the Chinook was an event in and of itself. It’s a pretty big bird and there seems to be a lot of work the flight crew has to do, just to get it up and rolling. LOL. But it’s such a great work horse, and an amazing thing to see taking flight, with it’s big counter-rotating main blades. Just another bright moment that day.

US ARMY Chinook CH-47D

US ARMY Chinook CH-47D

One of the last birds out, was the DEA Eurocopter. The pilot took off with a standard departure to the south, but at the end of the field, kicked the rudder hard over, banked it high and came back down low over the flight line, before completing a standard northern departure. All of those helio pilots sure seemed to love their jobs!

LEO - Eurocopter AS 350 B2

What a great event at the Museum of Flight. Even the bad weather did not damping the activities on the flight line.

It was fantastic to meet and learn from these American Heros. The people out there on the front lines of national defense, law enforcement and search and rescue. It really makes me Proud to be an American.

Loud helicopter, light sleep and a camera

I can’t remember the last time one of the helicopters woke me up. This morning that streak was broken at 05:14.

I’m not sure why, but the typically quieter EC-135 helicopter woke me straight up out of a deep sleep. I’m sure it was a deep sleep since I was somewhere off in dream land, and suddenly finding myself looking at the helicopter’s spot light as it landed. Why, or why.. on my day off, did it wake me up at 5 AM?

All was not lost though. A project idea I’d been toying with for some time, could be tried. Some long time exposures of the helicopters arriving and departing the hospital.

Catching them in time to get landing shots, that’s going to take quite a bit of luck (they are fast, and often you can’t hear them until they are on final). However, grabbing some photos of take-offs only requires some patience. This time, it was almost an hour of poking around the house waiting for them to leave. But when they do, it’s all business. I typically have 2-3 minutes (maybe less) to get setup after they fire up the engines.

While waiting I tested out some exposures, macro and zoom shots, different white balance settings, ISO and apertures. When you have an hour to kill, this is not so hard.

First shots were to bracket the time, exposure and ISO settings:

Exposure and ISO settings
Time: 30 seconds
Aperture: f8.0
ISO: 100
Focal Length: 400mm
Night photo of AirLift Northwest EC-135 -- tail N139AM

Finally, at 6:00AM they fired up the engines and prepared to depart. Interior of the helicopter is light with bright blue light, which is visible in this photo, and also to the naked eye. I’d always thought that night aviation lighting was red, especially since blue light has a wavelength that is more difficult for the eye to focus upon. Perhaps there is a light barrier between the medical section and the cockpit.

Exposure and ISO settings
Time: 30 seconds
Aperture: f9.0
ISO: 100
Focal Length: 340mm
Night photo of AirLift Northwest EC-135 -- tail N139AM

This one I cropped at a different aspect ratio to provide a little more perspective. Sort of a ‘lone helicopter in the night’ sort of shot. Not really that ‘lonely’ looking on top of a brightly lit hospital. It’s a first set of shots to see what I can learn.

Exposure and ISO settings
Time: 30 seconds
Aperture: f22.0
ISO: 100
Focal Length: 100mm
Early morning departure -- N139AM

Finally, The Shot. Or really, the concept s shot I was going for. It did not turn out as I had expected, but I was still pleasantly surprised at the result. I opened the shutter right as the pilot pulled pitch, and the heli started to lift off. It remained open until well after it was out of frame. Typically they have on a spot light on during takeoff, but I did not see, nor the the camera capture one this time. I don’t know what it might have looked like (blown out photo, perhaps), if it had been on. Regardless, it’s close to what I was going for. If you put on a tin-foil hat and listen to Art Bell, you might think this is an alien landing. Use your imagination as you see fit.

Exposure and ISO settings
Time: 30 seconds
Aperture: f22.0
ISO: 100
Focal Length: 100mm
Night photo of AirLift Northwest EC-135 -- tail N139AM

More Night Photography – ALNW EC-135 EuroCopter

A few nights back, I had the opportunity to try my hand again, at some night photography of the helicopters.

This time the subject is an EC-135 EuroCopter Air Ambulance.

Photography at Harrison’s Hospital during lift-off.

AirLift Northwest EC-135
AirLift Northwest EC-135
AirLift Northwest EC-135
AirLift Northwest EC-135
AirLift Northwest EC-135
AirLift Northwest EC-135

Airlift Northwest – N951AL Night Photos

Last night, around 1:00 AM I popped outside to try some free-hand night shooting with the Canon 50D camera. Being so early in the morning, light was basically non-existent. I’ve never shot the camera at such and extreme ISO. It’s and experiment to see what noise levels are experienced at those speeds.

There are camera body options to push the ISO to an incredible 6400 and 12800! I have no idea what the noise level would be with those settings, but the next chance I get to photograph the helicopters at night, I’m giving it a try.

For this mornings experiment, I armed myself with the 5.6f 400mm lens and ISO set to a whopping 3200, I took my best shot(s) (so to speak).

HobbyKing HK-T500 First Look

Part of my latest toy delivery was a slightly larger heli than I’ve worked on before. Not wanting to get too far into this before I learned something about the 500’s, I purchases a basic intro kit.

The current plan is to build this kit, screws up, put together a full parts list and get a good estimate of what a real flying 500 will cost to build, with common spares, electronics, batteries etc.

So, onto the kit.

First, this kit arrived in a box smaller than my EXI-450 did. The way the packed the stuff in there was really something else. Here is what the array of parts look like once unpacked:

Hobby King HK-T500 Helicopter Kit

So, just exactly how large is the main frame? Pretty big.

Closer look at the 500 class alloy frame

Comparison to a fully assembled 450 behind it.

Alloy frame and once piece landing skids. 450 Heli sits in background.

Landing gear is a one piece plastic affair. Checking the parts list on the higher-end HK-500GT shows that it uses a multi-piece gear assembly, more in line with 450 kit I have. A detraction, but one that can be solved with the purchase of a 500GT landing gear set (about $5.00).

Once piece plastic skids in T500 kit.

Main rotor bearing block is plastic. I had a small issue on the plastic bearing block in my 450, and ended up replacing them with alloy. Checking parts I see that HobbyKing does sell an alloy block for the GT version, however it very clearly states that it DOES NOT fit the T500 model! That could be a major issue ongoing. When they say that it does not fit, I don’t know if that refers to locating pins only, or if the overall dimensions are different enough to prevent use.

T500's plastic main bearing block.

The kit does arrive with a set of fiberglass main rotor blades (black / yellow). As you can see, these are not just a little larger than those of a 450 (middle) and more than twice the size of a 250 (bottom, shown for effect). These blades are not only big, but they are heavy! Fiberglass 450 blades I’m using come in at 18.5g each. These bruisers weighed in at 68.6g!

Rotor blades, 500, 450 and 250 class.

Main gear set seems serviceable. Operation seems fairly smooth. The trail drive gear is a little wobbly, but that’s been the case on every gearset I’ve seen so far, including a factory Align unit. I’ll take it apart and re-oil the one-way bearing. I did notice that it has not ‘fan blade’ properties to move air like some of the other 450 gearsets I’ve purchased.

Main gear set.

Tail boom, servo link, boom support rods and flybar are all in the next package. The tail boom support struts appear to be plastic with plastic ends. Tail boom is typical aluminum alloy. Flybar appears to be stainless steel and quite rugged.

Tail boom parts package.

Servo link ends are plastic, but it does not look quite like the quality ball end links typically found in kits. Maybe it’s just the size of them.

Closer inspection of boom parts.

Boom holder and tail gear set is a festival of plastic, right down to the cross tube/spacers that screws anchor into. Even on the cheapest of kits I’ve seen so far, that was metal (talking about the 4 bars near photo center). Is it ‘bad’, I don’t know, but I’d prefer to have seen some more metal in there, that’s for sure!

Tail drive gear box.

Assembly looks pretty straight forward. Which is good, since they clone kits do not come with any sort of instructions. All the parts fit snug, and turn freely. The screws in the tail kit are allen-drive, but they are on the soft side. While test fitting the parts, without even torquing them down, one of the heads stripped out, requiring the application of a small vice-grip pliers to remove it. If it had been snugged down, it would have been a much more difficult task. I’m considering a trip to Tacoma Screw for a set of torx-drive replacements

Tail drive gear box with gears and bearings test fitted.

The tail and tail boom fastening components are all in the next bag:

Tail drive and boom fastening parts.

Tail gearbox, blade holders and pitch actuator arms are plastic. Bearbox is nearly completely enclosed, so I’m not able to see the tail drive pully gear, but it also appears to by a white nylon/plastic.

Tail rotor drive and gearbox detail.

Knight head, tail rotor fin and tail servo holder are made of metal alloy. Tail boom yoke and servo boom holders are black plastic material.

A lot of stamped alloy parts in this bag.

Probably the most important part of all, the main rotor head. One word comes to mind; PLASTIC!. Lots of it. First the overall shot:

Main rotor head assembly.

Main head, it’s a beast. 132mm across (grip to grip) it’s 33% larger than the same part of a 450. And, aside from the feathering shaft and bearings, it’s all plastic. Having broken a plastic blade grip on a 450 recently, a similar crash might crack the entire fly head on this bad boy.

Main rotor blade grip and feathering assembly.

Swash plate on this is part composite, part alloy. Linkages seems appropriately constructed on the head and swash. Pictures can be worth a few hundred words, so here is the picture.

Main rotor head, swash plate detail.

Another of the links, washout arms and tracking links.

Main rotor head details.

Flybar paddles. Plastic. I’m not sure what the deal is with the vents, and the pack of decals. Based on what I’ve seen on other photos, the decals are applied to the blades to cover the ‘vents’. Perhaps those are simply there to lighten the paddles, and the decals cover the holes to make the paddles work. I’ll have to look into this further.

Flybar paddles and decals.

Anti-rotation bracket and canopy stays. Also….. (wait for it….. waaiiiiiiiiit). Plastic.
[PIC 20]

One last package of stuff. Hardware, blade holders and two different sized pairs of hook-and-loop straps. Also in the bag are two sizes of velcro adhesive pads, two bags of extra fastening hardware, servo horn accessories, balls and a pair of monster motor pinions. Of note in this bag, is also a bottle of purple 222 thread lock. I already have a monster bottle that I have used on all my kits. I just find it interesting because just about everyone is using the heavier duty blue which I’m certain is the WRONG type. Having more than a passing background in auto and motorcycle repair, you need to use the right locker for the right size fasteners. Blue (242) is really for much larger hardware. Purple (222) is the right stuff for small fasteners. Now I have a little validation (beyond what the TRex assembly manuals show) with the inclusion of 222 Purple in the kit. Good to know!

Last general hardware parts bag, revealed.

Last is the canopy. And it’s BIG. The canopy stay holes also need to be enlarged to work with the supplied (white this time) rubber bushings. That is one of the first things I’m going to do, since I want to design at moderately nice looking canopy design for this monster.

It would be harder to send a cheaper canopy! It’s simple resin, like EXI-450 kit supplies, but in this case it does not have even have the ‘cockpit’ canopy detail on it. It’s just… all white. I put a spare 450 canopy in front, and my coffee mug in the photo to give some scale.

T500 and 450 canopy scale comparison.

So, there you have it. Unpacking the HobbyKing HK-T500 electric R/C helicopter kit.

Building new micro helicopter – N250HKA

Just arrived!!!

HobbyKing 250 GT Helicopter Kit

My latest toy box (or box of toys) arrived during the conference this week. I’ve had a lot of time to work on building this machine, but I did manage to get some HXT-900 cyclic servers and a general test/fix mockup completed. ! I still have to order several parts before it will fly.

  • 250 / 300 class ourunner motor (400 won’t fit.. bummer)
  • Micro head locking gyro
  • Digital tail servo
  • DSM2 compatible receiver.

N450V2A – post crash repairs underway

Bent tail boom after crash
Repairs are underway, following my flight yesterday, where I ran out of altitude. Breaking things is seldom enjoyable.

But it’s the risk you have to take if you’re going to fly these things, especially when there are gusty winds. There are plenty of YouTube videos showing real helicopters having trouble with wind, sometimes with tragic results. I

In the grand scheme of things, a little bit of bent aluminum is hardly much to worry about. Being grounded with a busted helicopter is still not the ideal situation.

I noted yesterday that the Blade 400 tail tube turns out to be remarkably similar in dimension to the one used on the 450. I really would have thought that the ‘smaller’ 400 class model would have a shorter tail boom, but it turns out to be about 15mm longer.

Comparison of Blade 400 tube (top) and EXI-450 tube (bent)

Easy enough to rectify. A little cutting, sanding and filing is all it took.

The new tail boom, and new Sport alloy tail case are now installed on the helicopter. One of the advantages of the new Sport tail case, is an alignment pin (the original did not have, it uses the hole seen in the blade 400 tube) that keeps the tail case from rotating. An issue I had a couple of times with the original part.

New tail boom installed.

A closer look at the alloy tail case, new tail rotor blades also installed:

New alloy sport tail case.

During lunch I’ll be able to finish mounting the tail servo, knight head and support bars.

UPDATE:
I just checked on the status of the replacement parts and some other fun stuff I ordered from China, using the ‘slow-boat 7-45 day shipping’ option. I regretted not spending the extra $20 for faster EMS 3-5 day shipping, until I checked the shipping status this morning!

For a slow boat from China (OK, it’s air post but the website said expect 7-45 days transit), it’s already here in the states. I just needs to clear customs. Not sure who long that will take but, you know I’m going to post here when it does!

Slow boat from China my ***! 🙂

N450V2A – Hover Testing

Finally, it was time to see if this thing would fly. And, if I can fly it!

This outing was my best yet! 3 full packs flown, no crashes, no rotor strikes, and only 1 really hard landing! I (of course) shot some video and uploaded it to my YouTube bucket.

Not never exciting to watch, it was pretty exciting to get it off the ground without flying back into it out of control! This is pretty fun stuff! Plus the gear-head part of me really loves all the micro-mechanical parts and seeing how they function together and make it fly!

N450V2A Overhaul – Completed

Tonight, I’m picking up where I left off yesterday [LINK], while I listen to some awesome local High School Radio (KNHC).

Sunday nights from 6PM -> Midnight is Industrial and Alt music show called ‘On the Edge‘. Reminds me of a similar show that used too broadcast on KFJC out of Foothill College in the Bay Area. Most of my good German Industrial music collection was the direct result of hearing it on that show.

Back to the Overhaul
I’ve been doing some research today on blade balancing. Picked up a couple of new tricks, talked to a few of the local experts and I’ve come up with what I feel is a comprehensive, but not exhaustive (aka anal retentive) balancing strategy. Here is my take on this VERY IMPORTANT task:

First off, getting some good tracking tape has proven to be a major challenge for me. Today I solved that problem, thanks to advice of a local flyer. He’s been using Monokote (I’m quite familiar with the heat-shrink version of it, having first used it almost 30 years ago). I picked up a high-vis red and contrasting orange in the adhesive backed variety.

Preparing to balance blades.

I don’t plan to balance the other 4 sets of blades I have tonight, just the set I’ll be using for the final run-ups once I have the bird back together.

The first step in balancing, is to find the COG (Center of Gravity) on each blade. I did this by rolling each blade on top of a spare flybar rod (it’s about 3mm in diameter) until I found the balance point. Once I did that I marked it with a permanent marker. This is done for both blades. The purpose of this is to determine how much balance weight you need to add to get the blades balanced our along each blade itself. Ideally you take the lighter of the two blades (if you have a scale that’s easier to determine, otherwise your normal blade balancing fixture will tell this tail), apply weight in the right locations to get both blades to have the exact same COG. I’ve done this already, the top blade has a little clear plastic tape used to weight it on the right side. Here the COG’s are in the same location on both blades.

Locating the center of gravity on each blade

Next I’m going to take equal pieces of the adhesive backed monokote, and apply a different color to the tips of each blade. Make sure the size of the monokote you apply to each is identical. They must also be applied in identical locations. Here is what it should look like *before* performing the final balance.

Adding contrasting blade tip colors. Critical to setting blade tracking

Next, set up the balancing rig and dynamically balance out the blades. Any weight, if required should be added to the light blade at it’s COG (which is why it’s marked across the pitch). Even though these blades are very close in overall balance, one blade does need a little bit more, to fully balance it out.

Blades on jig for balancing.

Once balanced, I moved back to the process of rebuilding the head. I had a lot of experience with the V2 head, but not the older Version 1 head that I had to buy parts for (no V2 parts available locally or online from the plethora of vendors, odd really). Interwebs to the rescue! I found an original ALIGN 450SE (v1) build manual with the exploded view of the V1 head!

ALIGN 450SE (version 1) exploded head view. (click image to enlarge)

Somewhere in the box of parts is the main head, and all it’s associated bearings.

Box of 450 class helicopter parts

The most important bag today, the main rotor head and blade grip components

There are a lot of parts that go into the grips alone! That’s 6 bearings, 2 spacers, 2 washers and 2 bolts, not to mention the 4 o-rings (dampners) and the feathering shaft itself (already installed in head).
Layout of all the parts required to assemble the upper rotor head.  Look at all those bearings!

Having the instructions made assembly straight forward and quick. It took longer to write this pragraph and take the photo, than it did to put together, install, locktite and tighten the grips. They seem very firm and turn very smoothly. A HUGE improvement over what I was attempting with the hybrid V2 guts and V1 components. I knew better, but I wanted to see how close I could get. Not close enough. At any rate, here it is, assembled.

Blade grips installed. This is a partially assembled main rotor head top-end.

The next step is to attach the rest of the upper head’s running gear. The flybar seesaw holder was a little problematic. Gunk in the bushings had it binding up. Finally resorting to application of some firearms cleaning techniques (and fluids) cleared up the gunk. Re-application of all locktites was of course required after being exposed to solvents. Added a little CLP to the bushings to keep the running smooth. Pitch arms were next and those when back together without drama. This is what I have now;

This is a fully assembled main rotor head top-end.

It was finally time to bolt the head to main shaft, insert flybar, line up the washout shafts and block, hook up swash coupling links and get ready to finish the top-end rebuild of this bird.

Upper, middle and lower sections of main rotor head assembled and installed. Swash Plate is that beast of link buttons on the bottom.

While upgrading parts, I decided to swap out the temporary Blade 300 flybar paddles (smaller, top) for the larger genuine ALIGN 450 parts. They are basically twice as thick, have actual airfoils and weight 8.8g, compared to the Blade 400 units which are 2.7g. The orginal EXI flybar blades come in at 4.7g. I tossed them out. One was not factory drilled for the flybar, so I just sorta hogged it out during original construction. Turns out that alignment of that bore is really important to the overall flight characteristics of the bird! They are gone, just in case I forget why they are no longer in use, and put them on something. I’m better off with the flimsy B400 paddles than one that is not drilled properly. Many lessons in these little things.

Temporary parts (top) vs. the right parts (bottom). Flybar paddles are critical to all Bell-Hiller head aircraft.

Installed, centered, measured, re-measured, checked for square, re-measured down to .001″ inch. with dial calipers. I’m sure how to get it any more accurately constructed than this! With the blades installed, it’s time to perform the first run-up and blade tracking test. Really, about 9 hours of work comes down to the this moment of truth. Fixed, same or (gulp) worse?

Assembled and ready for ground tests. Stand by for....

This video contains the first run-up, before blade tracking was adjusted. Next was post-tracking adjustment. Overall vibration has been reduced significantly! With the replaced bearings and slightly slower head speed the entire things sounds healthier too. Another view in the video displays the blade tracking, and finally a fully assembled bird is run up to 3/4 throttle. A test of the throttle cut and auto-rotation flare action is also examined for function.

Everything looks great and ready for another test flight! Local time on the Pacific Coast here is 23:07. A little too late for test flights. The plan is to give it some air time after work tomorrow.

One other thing I noticed, was that flybar action is much smoother since I completely tore down the head and rebuilt it.

The upside of all this, is that I’m 100% confident I can repair any damage done during a crash, including a full frame up-reconstruction. At some point this fall I’ll probably swap out the metal frame for a V2 carbon fiber setup (about $30). That will drop quite a bit of weight off, and going to a CF tail boom will also shed some weight. The less the entire thing weighs, the less power it will use to remain aloft, which equates to lower operating temperatures for bearings, and longer flight times with the same batteries.

Now, I rest.