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Vintage Kyosho Concept 30SR-X E-Conversion...

heli_headcaseKey Veteran - Hovering around Atlanta -

HEY!

I couldn't help myself and after thinking for a couple years how to make a Concept 30 fly on electrons - without needing a CNC mill to make a special motor mount - I brainstormed this conversion idea.

First some background: I was a strong advocate of the Concept heli line through the 1990's and have really missed flying these models. As a field rep for the then Kyosho importer, Great Planes, I did my fare share of flying, modifying and crashing these plastic heli's. Always had a soft spot in my heart for them and also a big collection of parts with which to resurrect a heli-or-two if the spirit were to move me.

Well, through some recent re-acquaintance of one particular Concept model, I felt the spirit swelling inside to make one of mine fly again but wanted something different - and electric. Have been working on the buildup and conversion over the last week, took progress pictures along the way and now feel it's time to tell anyone that's even slightly interested what I've done. I'm only showing what I did to make this heli fly, not offering a conversion kit (not at this time but maybe?) and to help anyone along that has a similar passion.

Ready? One picture to start:

Let the discussion begin!


HHC

So many heli's - too little time...

07-09-2011 Over year old.
cgbole

Elite Veteran

Tulsa Ok. U.S.A.

Nice..What motor and cell count are you running? I started out with a Concept 30 around 1995. Brings back a lot of memories man..
thanks for the pic.
chuck

Synergy / Thunder Power / Esprit Model / Scorpion Power Systems

07-10-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Motor & Pack...

At this moment I'm using a variety of 5S packs between 3700-4500mAh.

Here's the custom-modded motor and its mount. Scorpion HK3026-1000 showing its extra long 5mm shaft.



The comfortable head speed with this combination is a wimpy 1600rpm, not ideal in my opinion. BUT, with certain known limitations in blade grip strength, wanting to use the motor, batteries and 520mm carbon blades I already had, I'll have to live with it for a while.

The overall handling qualities are outstanding and with the power this motor can hand out, it outclimb any OS32-powered stock machine.

I am planning on getting some 3700mAh, 6S packs which has the potential to put the head spinning closer to 1900. But until I either replace the plastic grips with Zeal metal units or dig up some <80g NHP 515 Razor Pro blades I'll play around with the 5S for the time being. Would rather not grenade this ship.


HHC

So many heli's - too little time...

07-10-2011 Over year old.
DougCart

Heliman

Port Charlotte, FL

Very nice!! Always loved the look and design of the older Kyosho heli's.

My first NEW heli was a Kyosho SX

07-13-2011 Over year old.
heli_headcase

Key Veteran

Hovering around Atlanta

My first Concept...

The first one I ever owned was a used 30DX but it was the first Nouveau Modern heli I tried to fly. Two years prior to me buying that Concept I was successfully flying my much-modified Du-Bro Hughes 300 (1974 vintage, 1989 mods) and instantly took a liking to the little Concept.

The only really new Concepts I owned and flew were easily counted on the fingers of one (complete) hand. That would be a Concept 46VR (preproduction kit) and a Concept 60 SRII Graphite Four-stroke (kit). I can't really count my C30SR-X-based, OS .21-powered drag racer as it was all custom parts save the tail rotor grips/hub, servo tray, canopy and main gear. But it was "all" new...


HHC

So many heli's - too little time...

07-13-2011 Over year old.
Mark Spies

Veteran

Houston & LaPlace

Steve,

Very nice job but that's what i would expect from you...LOL

Team Can't Get Right

07-13-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Side View of Drive System...

Thanks Mark. Your E-Horizon looks like a real winner too. I'm half tempted.... "Somebody STOP ME!"


HHC

So many heli's - too little time...

07-13-2011 Over year old.
Mark Spies

Veteran

Houston & LaPlace

Hope to have the other CCPM electric finished for IRCHA...will we see you there?

Team Can't Get Right

07-13-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Overall Assembly...

Here's the final assembly of the motor, mount and battery compartment. The space once used for the fuel tank and (period) mechanical tail gyro is damn near perfect.

The mounting plate (carbon) for the Castle ICE 100 ESC keeps the electronics out in the moving air and the space inside the frames clear for loading the battery pack.



HHC

So many heli's - too little time...

07-13-2011 Over year old.
heli_headcase

Key Veteran

Hovering around Atlanta

No IRCHA 2011 for me...

...will we see you there?
No, not this year. Y'all have fun, y'hear!


HHC

So many heli's - too little time...

07-13-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Left Frames - Open Space...

The battery pack has a straight-load-shot from under the motor and into its tray. Well supported and not too difficult to swap out.

Can anyone tell me what that angular 'thing' is bolted to the original engine mount?



HHC

So many heli's - too little time...

07-13-2011 Over year old.
cgbole

Elite Veteran

Tulsa Ok. U.S.A.

"Angular Thing" Pretty slick man. Use a slimer crankcase for a counter bearing of sorts..

So what did you do for the extended motor shaft?

chuck

Synergy / Thunder Power / Esprit Model / Scorpion Power Systems

07-14-2011 Over year old.
badbill

Senior Heliman

Centerville, Georgia

That is awesome!!! So tell me, what inspired it???

Bill Davenport
AMA 28141

07-14-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Die Slimer Die...

I insisted on using some means of supporting the motor shaft and clutch assembly. First thought was to machine a custom bearing block to bolt into the Concept's engine mount. Wait, there's an easier way. Use a dead OS28/32 and cut away all surplus metal leaving only what's needed to hold a bearing out there. I'm not going to go through all the permutations of my thinking process to get to where I did but I knew I had many more dead Enya .35SS heli engines from which to pick a suitable case donor.


Here's a good .35SS compared to the salvaged case. By the way, the bearing used as the shaft supporter is 26mm OD vs the Enya's 24mm OD. I didn't have any way of protecting the balls of the 24mm bearing from contamination (open bearing) and had some double-shield 26mm bearings in my stock of bits. Caused me to have to open up the forward case housing but the bore (from Enya) of the 35's cylinder block case was 26mm to begin with.

The motor shaft was some recycled 5mm steel rod most likely from an old photocopier. Those machines are a veritable goldmine of mechanical goodies! Here's the original shaft next to the motor containing the long shaft:

...and here's the motor shaft adapter that is supported in the 'slimer' bearing and drives the clutch assembly:


HHC

So many heli's - too little time...

07-14-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

"Bad" Inspiration...

So tell me, what inspired it???
As I hinted in the beginning of this thread:

"Well, through some recent re-acquaintance of one particular Concept model,..."

Bill, it was YOUR FAULT! ... Mostly... Thanks for that push I needed to get back to flying one of my favorite heli's some 15(?) years later.

Here's Bill's model. Ignore the canopy - I put mine on Bill's Concept so it would have a 'face' while test-flying. His, when finished, will look very similar.


HHC

So many heli's - too little time...

07-14-2011 Over year old.
v22chap

Key Veteran

Granger, Indiana

Way to go Steve ... that is one sweet model with a now sweet mod. I too loved my Sr and Sx concepts for many yrs ... may have to pick one up and do this ... Thanks for sharing ..

Larry C ----------Bergen R/C helicopters

07-14-2011 Over year old.
Heli143

Elite Veteran

Phenix City, AL

Steve that is so cool!!

you do some very nice work sir!

Roy Mayoral

07-14-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

Got you covered...

may have to pick one up and do this ...
If you're serious, Larry, I can provide some rough (hand-drawn) dimensional drawings of all parts used in the conversion. Just be warned here: That Scorpion motor, as small as it is, will not hesitate for one second to rip the teeth right off the main gear.

I grossly underestimated the torque it can provide on 5S power, even being fed through the centrifugal clutch, and ended up 'trimming the teeth' on the gear I first installed. The Concept main gear flexes too easily down and away from the bevel pinion under load and this 'stupid' little motor had far more potential torque than any .32-.37 nitro I've ever seen. Back in 1994, while at IRCHA, I did experience a mild gear strippage while testing a piped OS32SX but that's when I learned to "over mesh" the pinion and main gear so they were preloaded together. That was of no help in this case.

But here's my solution:


HHC

So many heli's - too little time...

07-14-2011 Over year old.
heli_headcaseKey Veteran - Hovering around Atlanta -

One More Pic...

Here's the best view of the gear support bearing:


HHC

So many heli's - too little time...

07-14-2011 Over year old.
DougCart

Heliman

Port Charlotte, FL

Very awesome!

07-15-2011 Over year old.
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Vintage Kyosho Concept 30SR-X E-Conversion...

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