RunRyder RC Helicopter Topic - Scratch building a 1/6th scale AH-56 Cheyenne

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Scale Model RC Helicopters > Scratch building a 1/6th scale AH-56 Cheyenne

Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Here is a Cheyenne update. The top cowl is nearing completion.This helicopter build has been an exercise in geometry, algebra, and mechanical drawing.

Any way as you can see it is really starting to look more and more like a Cheyenne. This helicopter is compound curve city!!!

Another cool picture of the real thing

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-04-2009 12:18 AM

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GyroFreak
Elite Veteran
Location: Florida ... 28° 52' N 81° 16' W

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This project is incredible and beyond the skills of myself, but I can dream. Wish I lived nearby and could be your apprentice to learn some of your model making skills and techniques.
Keep up the postings and hope your shoulder is healing well, gotta be tough working on such a large model with a bum shoulder.
Thanks for detailed postings.
Paul

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08-04-2009 12:49 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Thanks Paul for the kind comments. You would be more than welcome to sit in on the build. It really isn't to difficult. You have to come up with a basic plan and then proceed. Balsa is very forgiving and easy to work with. One thing I do is I make preformed shells on a form for most round surfaces. I will post a picture of a shell being formed in the next up date. As to the weight, at this point it only weighs about 3.5 lbs. So it is still very easy to move around. Now my Vario Bell 47 G3; that's another story.

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-04-2009 01:40 AM

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GyroFreak
Elite Veteran
Location: Florida ... 28° 52' N 81° 16' W

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Thanks Richard,
I want to add a semiscale S-55 to my 700E someday, maybe I can get the courage to take a stab at it after following your build. I have previously thought about balsa coated with resin and reinforced inside at critical spots with fiberglass, but every one else seems to do the foam plug to make a reverse mold, then fiberglass. My luck I would get it permanently stuck in a mold.
So if I understand this, yours will be a one off built up balsa reinforced with various techniques, am I following this right ?

Bacteria They're the only culture some men have
Growing old is mandatory; growing up is opti

08-04-2009 03:38 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Hello again Paul:

No, actually it is being built as a plug. I will be popping some of these from the completed molds. The balsa build up method was chosen because I was not able to get some of the other drawings I was looking for. So the plug is being built old school style.
This entails building a laminated box with ample materials in the corners to carve and sand away to create the final shape of the main fuse.

Now if I were to just be building a one off I would make just a few adjustments in the balsa build and then coat over it with glass cloth and epoxy resin (not polyester resin). Not a lot would change.

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-04-2009 03:46 AM

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GyroFreak
Elite Veteran
Location: Florida ... 28° 52' N 81° 16' W

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Thanks Richard, maybe I will still try mine after I follow yours thru to completion. I just hate working with any amount of fiberglass. I did a plug and mold once for a very simple 1/2 box shape with rounded corners and the dang thing got stuck at one corner and I ruined everything getting it unstuck. Maybe the newer spray mold release agents are better than what I had many many years ago.
Thanks I I will be watching and learning.

Bacteria They're the only culture some men have
Growing old is mandatory; growing up is opti

08-04-2009 03:54 AM

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bwellmaker
Veteran
Location: Long Island

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Richard,

This project is really looking great.

Butch

08-04-2009 01:55 PM

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jmkirsch
Heliman
Location: Rochester, NY

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Richard,

Awesome job! Can't wait to see the finished product.

What size mechanics are you building this for?

--Jake

08-04-2009 04:34 PM

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papatango
Veteran
Location: Toronto, Ontario, Canada

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Subscribed; this is an incredible build project. Can't wait to see more of your progress.

Best of luck Mr. Morgan.

Patrick

08-04-2009 04:50 PM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Hello Jake:

I am considering installing my Jetcat PHT 3-3. But I believe the electric mechanics that are going into Butch's (bwellmaker) S-76 as seen here on RR would be great in the Cheyenne. Those are by "Peka". The Vario R-22 mechs would also work just fine. I bet the Vario mechanics designed for the Bell 47 G-3 would work as well. I think there would be a lot of possibilities! It is my intent to keep it light and to provide extra strength with CF in the fuse where needed.

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-04-2009 06:28 PM

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Hoverup
Elite Veteran
Location: Gulf Coast

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Every post of yours in this thread Richard just builds the excitement. Great work.

Cheers - Boyd
AMA 80393
IRCHA 3355
Major USAF
Retired

08-04-2009 09:38 PM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Hey Guys:

Here is little update on the top cowl construction for the Cheyenne. Whenever I need to form a balsa shell, I always form it around a paper/cardboard shipping tube. I have several different diameters. The reason for using a paper tube is to allow for complete and even drying rates on both sides of the balsa sheet. If you use some other material, the formed shell can't "breath" to allow for uniform drying, which could result in warping and splitting. Also use blue automotive body tape. This low tack tape won't tear the face grain of the wood away when you remove it. Also make sure to criss-cross the tape, and only just tight enough to hold it securely against the form. Another tip is to let the balsa soak in warm water with some dish detergent in the water. This breaks the surface tension and allows the wood to absorb the water more freely. Keep the wood completely submerged for no less than 3 to 4 hours. Then put it on the form for 24 hours and viola!!

Note: leave the balsa shell on the form until you are ready to use it. Wood has a memory and will try to flatten out resulting in warping.

Wood selection for this process is important. Use only open straight grain wood that is of medium soft density.

Here are some pictures of the process.

More to come!

Water soaked balsa being applied to the form with blue tape

Now dry and being removed from the form

The dried and formed balsa shell

This is where it goes

Notice the fit with out trimming. Perfect!

Here is the formed balsa shell installed on the top cowl of the Cheyenne

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-08-2009 02:21 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Just a quick Saturday update. The top cowl is now finished. This part of the project has been a real butt kicker, just in trying to determine the next phase of construction. Now it is time for some balsa block caving for the intakes and the exhaust shroud extension. Here are some more pictures of the cowl and three more of the Cheyenne trying on its main rotor and a pusher prop.

cowl detail left side

Left side from nose to cowl end

Trying on the main rotor and a pusher prop
and starting to look kinda badass!

Trying on the main rotor and a pusher prop

Trying on the main rotor and a pusher prop

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-08-2009 11:44 PM

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DBlum
Heliman
Location: Raleigh NC

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Richard, really enjoying the build thread and great job you're doing there. It's going to be awesome when finished.

Dave

08-09-2009 01:58 AM

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Hoverup
Elite Veteran
Location: Gulf Coast

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You're turning and burning Richard.

Cheers - Boyd
AMA 80393
IRCHA 3355
Major USAF
Retired

08-09-2009 02:10 AM

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Wayne Parrish
Senior Heliman
Location: Apex,NC,USA

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Richard, That has got to be great therapy for that shoulder ! Beautiful work ! Wayne

08-09-2009 02:48 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Thanks guys, I appreciate your comments. This is a project that I have wanted to do for some time. Back in the day, I use to build my pattern and scale war birds out of balsa and fiberglass so this is like visiting an old friend. Wayne you are right this has been good for my shoulder. The Cheyenne is basically a hollow box, so it is still very light. The shoulder does slow my progress, as I had hopes of getting some of the fiber glassing done this weekend. We will see where I end up tomorrow.

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-09-2009 04:40 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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I was able to get the exhaust diverter carved out and installed and then my arm said that’s all. Here are some pictures of the completed diverter. It is designed in this fashion to divert the jet exhaust and residual thrust up and away to the right against the torque of the main blades.

Right side aft shot of the exhaust diverter.
Notice the angle.

Left side shot of the exhaust diverter

View looking down onto the exhaust diverter.
Yes, this is the way it is supposed to look

Side view from below

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-10-2009 01:34 AM

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Richard Morgan
Senior Heliman
Location: Virginia Beach, Virginia USA

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Darthdrk sent this link. It is great short vid of the Cheyenne in action.

http://www.youtube.com/v/XE0CrIup6Uc

http://www.youtube.com/watch?v=4w85...r_embedded#t=33

If the link does not work copy and paste into the browser.

I am building the wings and tail surfaces at this time. New pictures soon.

Richard

Is it just me, I thought all Helicopters flew in 3D......Hmmmm?

08-14-2009 04:54 AM

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Hoverup
Elite Veteran
Location: Gulf Coast

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Man, that really gets the juices flowing. Inspiration for the builder.

Cheers - Boyd
AMA 80393
IRCHA 3355
Major USAF
Retired

08-14-2009 04:28 PM

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Scale Model RC Helicopters > Scratch building a 1/6th scale AH-56 Cheyenne

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