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HelicopterAntiques or Out of Business › RE: Kalt Pilots...all gone?
12-01-2007 08:56 PM  9 years agoPost 1
BeltFedBrowning

rrKey Veteran

Kansas City

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Hello- Just thought I would share my obsession with keeping my Kalt Alpha gassers in the air. I Stripped the main crown gear long ago on both of them and the gears(or any other parts) are not available. I have fitted My Kalt gassers with a belt drive tail from a JR Vigor. I also use the Vigor main gear. I have had zero problems with this setup and I absolutly love to fly the Kalts. The Kalt 22cc engine has loads of torque and is rocket fast in FFF compared to my JR gassers. It is a very stable flier which makes it suck for 3-D but I love to fly it just because of the forward speeds this bird can achieve. I am also using modified Hirobo main shafts to replace the soft Kalt main shafts.
Oh- yes that is a Predator canopy and fins and I use the century V2 muffler. Thanks a lot for looking and keep 'em flying!

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12-01-2007 11:21 PM  9 years agoPost 2
BeltFedBrowning

rrKey Veteran

Kansas City

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Kalt conversion

Ok. I've had some interest in the Kalt belt drive conversion so I will outline it here. The Kalt Alpha has a carbon stiffener on the side of the main frame, I used this for my template. You can see in one of the pictures I have made a new one out of aluminum and it has some extra material at the back for the bearing blocks which support the new JR pinion to drive the belt. The holes for the bearing block bolts are slotted to set the gear mesh.
The bearing blocks and the tail boom support clamps are wider than the frame so I sanded both sides where they bolt up to reduce the width. I thought later that it would have been simpler to use spacers and longer bolts on the sides of the Kalt bearing blocks to just make the frame a little wider. I had to use a bearing block from an Ikarus Eco 8 for the top of the tail belt drive gear because there isn't very much room between the frames.
The Hirobo mainshaft is the best fit I could find. You just need to cut a groove along the length of the shaft for the pitch slider rod. I used an air powered cut off tool but a dremel could also be used. The head will be a little higher so the linkages will have to be lengthened. The Vigor main gear will bolt right up to the Kalt autorotation hub but the dish is different so I had to put a few 10mm shims to lower it about 1.5mm. The tail output shaft is the same diameter so the Kalt tail blade grips and slider can be used. I have been flying them this way for a year with very little mainenance and no stripped gears. Here are the parts, most of them are from Rick's. The Ikarus bearing block is from fxaeromodels.

-mainshaft- Hirobo 0414-111
-maingear- jrp960002
-Tail belt drive gear-jrp970096
-bearing block- jrp960018
-upper bearing block- Ikarus 67521, they also have an aluminum bearing block that could probably be used for both upper and lower pinion drive bearings, it is narrower. DMT1006. The bearings will have to be purchased for the Ikarus bearing blocks to fit the drive pinion.(easy)
-belt pulleys-jrp960190, jrp960187
-tail boom clamps- jrp994003
-tail boom- jrp993002
-belt- jrp960188
-Tail output case set- jrp996023 orjrp960325 (upgrade)
-tail output shaft- jrp960180
-tail rotor lever- jrp996025
-tail rotor slide ring- jrp960050
-tail blade grips complete- jrp960470 or use the kalt

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12-02-2007 04:45 AM  9 years agoPost 3
AltecLansing

rrElite Veteran

North Carolina

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how did you drill down the center of the mainshaft? They aren't hollow all the way through. By the way, I do have 4 of these mainshafts already modified. Well, 3, 1 isn't drilled all the way through. I have no way of getting it drilled either.

Man, I miss the eighties.

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12-02-2007 04:52 AM  9 years agoPost 4
toejab

rrApprentice

Buffalo ,New York area

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i am wondering if in this modification...can the original kalt main gear and main shaft be used?usually only the top bevel gear gets stripped of teeth.

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12-03-2007 05:31 AM  9 years agoPost 5
BeltFedBrowning

rrKey Veteran

Kansas City

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Kalt conversion

To use a different brand mainshaft you just need a slot or groove down the side so the pitch rod can recess into. Your Kalt mainshaft already has it. You will never drill a hole in a hardened mainshaft. That is why I use the Hirobo mainshaft it is about the same length, it just needs a groove cut down the length of it for the pitch rod which fits under the slider. Only a high speed abrasive cut-off wheel will do. Either a dremel or a air cut-off tool will make short work of it. Make sure it is in the same spot in relation to the upper jesus bolt on the old one or your links will be 90 degrees off .
The Kalt main gear and mainshaft will work nicely. If you have been into Kalts a while you probably have plenty. I only had the ones that came with my 2 Kalts so I had to find a long-term fix. The holes for the head and one way bolts are already drilled in the mainshaft so no drilling is required. I tried JR and Century mainshafts but they were too short. they could probably be installed but the head would be closer to the frame and your pitch range would be decreased.

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12-03-2007 08:00 AM  9 years agoPost 6
human213

rrVeteran

malibu

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Love my omega four stroke...

michael

Not everything that can be counted counts, and not everything that counts can be counted.

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12-03-2007 10:18 AM  9 years agoPost 7
AltecLansing

rrElite Veteran

North Carolina

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I have enforcers, my mainshafts have to have a hole down the center. I've got 3 modified like this already. I use the sceadu too. Its a pretty good mainshaft for this mod.

Man, I miss the eighties.

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12-03-2007 03:18 PM  9 years agoPost 8
BeltFedBrowning

rrKey Veteran

Kansas City

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enforcer main mast

Hey altec can you use a Raptor 30/50 mainshaft in your Enforcer? It is 10mm and already hollow.

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12-03-2007 04:20 PM  9 years agoPost 9
BeltFedBrowning

rrKey Veteran

Kansas City

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Gears

Hi toejab

I cut the groove in the main shaft with an air cut-off tool. The cutting wheel was the right width so I only had to make one pass. I put a piece of masking tape down the length of the shaft and made several passes down the edge of the tape. The depth really isn't that constant, they are just crappy pictures. If the groove isn't straight enough to let the rod moove freely just run the tool down one side or the other until the pitch slider/rod mooves freely. The Century bevel gear is CNHI60508B. The JR gear is JRP960002 no bevel. Here is a picture of the Century predator black main gear with a bevel on it. You see the problem with the modern bevel gears, they are too low in the main gear. There is also a pic of the bottom of a Kalt gear showing the hollow groove under the bevel. If it didn't have this we could just machine off the bevel and bolt on the Century bevel.
Kalt gear and tail drive
pinion. lots of room between
bearing block and gear.

Century predator gear
The Kalt bearing block
hits the gear before the
pinion can mesh with the
bevel gear.

Here is the Century
Predator 90 tooth
gear with the Kalt gear

Jr 88 tooth gear
with Century bevel
just sitting on it
next to Kalt gear
Needs a spacer machined.

Jr gear without bevel
and bottom of Kalt gear
showing hollow under bevel.
If only the kalt gear was solid
on the bottom, we could machine
off the bevel and bolt on the
Century bevel.

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12-03-2007 06:49 PM  9 years agoPost 10
toejab

rrApprentice

Buffalo ,New York area

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thanks to all for the new ideas.i also have the enforcer zr ,so now i have a source or two for the main shaft. i am going to try and add some pix here like beltfedbrowing,hopefully they will be o.k. the first one will be the same 88 tooth jrp960002 gear used by beltfedbrowing. it has what i was told to be a KALT bevel gear mounted on it. that set-up requires no spacer as the height of the bevel gear is perfect!...unfortunately i only had the one.it would be nice to find that it really wasn't a KALT bevel gear,but one from a current production heli.....the next pix is one of the same jrp960002 gear mated to a jrp960111 96 tooth bevel gear. a machinist friend pressed in a material that looks to be the same as the gear,and turned it on a lath so that it was a solid gear on one side.then installed the bevel gear with bolts. looks good,haven't tried it yet.i will get one of the other CENTURY bevel gears to compare it. thanks again to all....larry

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12-04-2007 12:00 AM  9 years agoPost 11
BeltFedBrowning

rrKey Veteran

Kansas City

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Bevel gear

Ok you guys got me all fired up and I finished the spacer for the JR/Century bevel gear. I used a JR 88 tooth main gear jrp960002 and a Century bevel gear 60508B 70 tooth. I haven't tried it yet but it looks promising. The mainshaft will have to be shimmed downward .175" or 4.5mm because the JR maingear sits higher on the hub.
The spacer is .175" thick and 2.65" in diameter. The center hole is 1.02" in diameter to fit snug on the one-way. I left a little lip in top to center the bevel gear, the lip is 1.137" OD. The four outside holes are threaded 3mm for the bevel gear and the four inner holes let the bolts pass through both gears, the spacer, and thread into the one-way

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12-04-2007 12:07 AM  9 years agoPost 12
RappyTappy

rrProfessor

North Denver, Colorado

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I have a Kalt Mercury 60 sitting in the garage with a box full of parts next to it. I stole the CCPM system and the bellcranks off of it and you can see them on my heli the Fuze 90 in my gallery, lol. One day I fully intend on getting the old Kalt 60 back in the air, of course its been a few years since I've been saying that, lol

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12-04-2007 12:11 AM  9 years agoPost 13
AltecLansing

rrElite Veteran

North Carolina

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I have the raptor 30 mainshaft. Its too short. I haven't checked it against the regular enforcer mainshaft, but I think its too short for that too. Besides the enforcer zr mainshaft is the better design, mainly because it is longer. I need to purchase a lathe to finish my last main shaft that didn't get drilled all the way through.

Man, I miss the eighties.

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12-04-2007 12:22 AM  9 years agoPost 14
BeltFedBrowning

rrKey Veteran

Kansas City

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Mainshafts

Altec- Have you thought about buying some 10mm mild steel rod. It would be easier to drill and most any machine shops could harden it for you when you are done. I considered this when I needed one for the Kalt Alpha.
I have a cheapie benchtop lathe that I got from harbor freight many years ago for $300 or so. It does the job but anything takes forever because only one axis is powered. the rest have to be cranked by hand.

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12-04-2007 12:32 AM  9 years agoPost 15
toejab

rrApprentice

Buffalo ,New York area

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beltfedbrowing....just wanted to say that it looks to be a strong set-up..nice job. i was wondering though if the 4 extra bolts were necessary.couldn't the 4 original bolt holes be used with longer bolts going all the way through to the one-way hub,tightening the whole sandwhich at the same time? there is probably something that i am overlooking here. larry

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12-04-2007 12:33 AM  9 years agoPost 16
AltecLansing

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North Carolina

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so, how many kalts does everyone have?

Man, I miss the eighties.

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12-04-2007 12:36 AM  9 years agoPost 17
toejab

rrApprentice

Buffalo ,New York area

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seven kalt 60 - style being their last few versions,one baron 30,a baron 50 and several enforcer zr's. and unknown numbers of parts LOL

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12-04-2007 02:15 AM  9 years agoPost 18
BeltFedBrowning

rrKey Veteran

Kansas City

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Kalts

I have two Kalt alpha gassers and eight non-Kalt heli's. Yes toejab the gear could have been attached with four bolts. The existing holes in the Century bevel gear are wider so I put bolts in them. I seem to over engineer everything. I thought the longer bolts would be more sensitive to shear forces and I had four extra holes not doing anything.
Any of you guys ever flown a four stroke heli. I want to put Saito's new FG36 four stroke gas engine in a heli. I can't wait to hear it!

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12-04-2007 02:18 AM  9 years agoPost 19
RappyTappy

rrProfessor

North Denver, Colorado

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Yep, flew a X-Cell 4 stroke before about 7 years ago, really nice. It had a real smooth and mellow tone and hauled some major a.. in forward flight.

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12-04-2007 03:10 AM  9 years agoPost 20
toejab

rrApprentice

Buffalo ,New York area

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well that must be what i was overlooking...i should have known that it would have 4 holes of its' own. i plan on getting some of those bevel gears real soon!.... let us know when it gets run up on your heli. thanks,larry

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HelicopterAntiques or Out of Business › RE: Kalt Pilots...all gone?
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