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HelicopterFuel-Helicopters New or Limited ActivityAvant › FBL e-Aurora w/ Scorpion HK-4525-520LE (lots of pictures)...
01-12-2011 04:21 PM  7 years agoPost 1
Justin Stuart (RIP)

rrMaster

Plano, Texas

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I've successfully installed the Scorpion HK-4525-520LE motor in my Avant e-Aurora. The motor fits very well in the helicopter and although it is slightly wider than the standard HK-4035-500 motor, it is considerably shorter making it even easier to slip into the frame.

I am using a Kontronik Jive 120HV ESC with a modified heat sink allowing me to put the Velcro strap though the center. I am hoping this will help with cooling. In addition, I placed the motor leads on the other side of the frame so that the ESC heat sink would experience maximum rotorwash. I have detuned the governor function of the ESC slightly using the Jive ProgCard to minimize current spikes and also to create less stress on the airframe.

If you look closely, you may notice a few small modifications I made to the helicopter frames such as drilling several small 2mm holes to permit the routing of wires and the attachment of the satellite receivers. I chose the receiver mounting locations to permit maximum visibility of the 2.4GHz signal. You might also notice a carbon fiber "sandwich" at the front lower portion of the right frame. This is to repair a crack I created from a hard auto.

I've got the RC-Booya quick release canopy mounts installed. I had to add a few washers to the rear mounts (between where they attach to the frame) in order to get the canopy to clear the main gear.

The routing of the wires and the placement of the batteries allows for a nearly perfect CG. It also allows all of the wires to remain neat and tidy. Electric helicopters (especially on 12s) can become quite obstructed with wires, but the e-Aurora allows many of these wires to be hidden.

The Rigid-Core FBL head is a real piece of artwork. It is beautiful as well as functional. The red marks you see on it are swashes of nail polish to remind me of what screws I have Loctited and which I have not. I clean all of my screws with acetone before installing them in order to maximize the strength of the Loctite 242 bond (the blue stuff). I find that the black powder coated bolts require the re-application of some oil on them 24 hours after being Loctited so as to resist the formation of rust.

At the top of the frames, you'll notice a Fromenco DC-UP capacitor bank which works similar to a NiMH "buffer pack" allowing the servos to pull high current without overwhelming the capability of the BEC inside the ESC. I am not using a separate RX battery pack.

It snowed in Dallas yesterday so it is still a little bit too cold for me to go out and fly, but hopefully it will warm up soon and I can get some flights on the helicopter. I am using ThunderPower 4400mAh 45C lipos, so I will set my TX timer to 3.00 minutes and see how many mAhs I use. It is my prediction that the motor will actually be more efficient than the 4035-500 due to the lower resistance wires, but when pushed hard will drain the batteries very quickly.

This new 4525-520 motor is actually only about 15g heavier than the old 4035-500 motor, so it seems reasonable that this motor and other ultra high performance motors like it will become a "must have" for 2011.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-12-2011 05:46 PM  7 years agoPost 2
rocket_33

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Mount Pleasant, Michigan USA

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That heat sink looks really cool

But that motor is what I would like to get my hands on. LOL If you don't like it you could give it to me hahah

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01-12-2011 06:02 PM  7 years agoPost 3
Ronald Thomas

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Gainesville, Fl, USA

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Justin you do some really nice work

Team MikadoUSA 480XXTreme, 550SX, 600SX, 700XXTreme, 800XXTreme!!

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01-12-2011 06:27 PM  7 years agoPost 4
Locktite

rrVeteran

N.J

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Very Nice setup.

Synergy 766 - SAB Black Thunder 700x2- Black Nitro 650- Align 700X/700N DFC SAB 500 Sport

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01-12-2011 07:43 PM  7 years agoPost 5
merlin3

rrKey Veteran

dayton, ohio

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why are you not using a seperate receiver pack, you know one of your main packs could fail or come unplugged. Other than that looks like a pretty good build

Justin - Team Horizon, Team Byron
2-700x, Trex 700n, small helis

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01-12-2011 07:51 PM  7 years agoPost 6
Justin Stuart (RIP)

rrMaster

Plano, Texas

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Thanks for the nice comments.
why are you not using a seperate receiver pack
The Jive has a good BEC capable of 5A continuous and 15A peak. Coupled with the 1.66 farad capacitor bank, I'm pretty confident I've got plenty of power to run the electronics. Yes, it is possible that I could lose one of the main flight packs, but for the sake of simplicity and saving another 5 or 6 ounces, I am willing to take this risk.

The capacitor bank gives me about 10 seconds worth of power to the electronics before the entire system shuts down. If for some reason the main motor cuts off due to a power failure, it is theoretically possible that I would have enough power to auto down. I think an ideal solution might be to have 2 or even 3 capacitor banks mounted to the aircraft since they do not weigh very much. This would provide redundancy for a good 30 seconds of flight time in the event the BEC fails or a main pack becomes unplugged. However all aerospace engineering solutions are a compromise between complexity, cost, and weight. Nothing is perfect.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-13-2011 12:12 AM  7 years agoPost 7
Taipan

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Sydney, Australia

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Very nice work Justin!

What is the AUW?

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01-13-2011 12:19 AM  7 years agoPost 8
remotemadness

rrApprentice

singapore

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OMG... now this is really making me wanting this more.. when will it ever come to the lion city..

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01-13-2011 12:25 AM  7 years agoPost 9
Justin Stuart (RIP)

rrMaster

Plano, Texas

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What is the AUW?
On my Ohaus scale (accurate to +/- 1 gram) the ready-to-fly helicopter weighs in at 5126 grams.

This equals 181 ounces or 11.3 pounds.

According to the Scorpion Power Systems website statistics, the 4525-520 motor puts out 4450 watts of continuous power (with a maximum output of 9600 watts).

http://www.scorpionsystem.com/catal...45/HK_4525_520/

I'd say that's a pretty good power-to-weight ratio.

If someone wanted to take it to the extreme, it might be possible to shave an additional 1 or 2 ounces off the aircraft by using titanium screws (or even aluminum screws) in non critical locations, shortening wire leads, using plastic gear servos with plastic servo cases, and eliminating some of the bullet connectors. Substituting 4100mAh or 4000mAh lipos could lower the weight even further, but at the cost of a very short flight time.

My goal is not to set a world speed record. I just want to have fun.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-13-2011 01:03 AM  7 years agoPost 10
Taipan

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Sydney, Australia

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Actually, more weight could help with setting speed records.

That is heavier than I expected with TP 4400mAh packs. Although those packs aren't that light either at about 705g each. I was expecting your heli to be around 4.8kg/10.6lb. Didn't someone have an E-Aurora that weighed 4.5kg/10lb??

My T-rex 700E weighs 5kg/11.0lb with 785g Voltz 45C 5100mAh packs and my Rave ENV 5.35kg/11.8lb with the same packs.

With flying, I've found anything heavier than 5.1kg doesn't do hard stops well so you're right in the ballpark! The Rave is excellent for big aeros - it's designed for F3C as well after all. Not so much hard smack unless you have a monster motor & insane headspeed.

I'm about to get a Kasama Srimok Faifa which will weigh the same as my 700E with the Voltz packs but keen to try the TP 4400mAh packs in it for 4.8kg/10.6lb all up which is nitro weight. Should be interesting! However my flying style is smooth 3D so helis that are too light are a no no as they don't track as well/or have as much inertia. I swear finding the sweet spot for weight is harder than finding the G spot in girls!

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01-13-2011 01:42 AM  7 years agoPost 11
Justin Stuart (RIP)

rrMaster

Plano, Texas

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Didn't someone have an E-Aurora that weighed 4.5kg/10lb??
I'm not sure how it would be possible to build the e-Aurora at 4.5kg/10lb unless they were using 3500mAh packs (or their scale was not properly calibrated).

At 5.1kg/11.3lb, my helicopter is not the lightest 700 sized helicopter around, but it's not that heavy either. My helicopter currently has a hollow main shaft which may save a little bit of weight. However the 8717HV servos I am using are not the lightest servos available. The 710mm "flybarless" main blades also weigh more in comparison to the lighter 690mm "stick banger" main blades.

I suppose it is also possible that my scale is not properly calibrated. However an individual TP 4400mAh pack weighs exactly 708g on my scale, and since ThunderPower has these batteries listed on their website as 708 grams, I am inclined to think my scale is reading fairly accurately.

For what it's worth, the airframe by itself (with the batteries removed) weighs 3710 grams.

I think that some of the 4.5kg/10lb helicopters that people say they have built were weighed using a cheap bathroom scale with an accuracy of +/- 1 pound.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-14-2011 07:37 AM  7 years agoPost 12
OICU812

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Edson, Alberta, Canada

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Get out there now and test it out!!!

...Once upon a time there were Nitros, flybars and frequency pins...

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01-14-2011 08:47 AM  7 years agoPost 13
Taipan

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Sydney, Australia

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+1!

I'm interested to see what flight times you get.

What gear ratio, HS & blades are you running?

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01-14-2011 10:47 AM  7 years agoPost 14
Justin Stuart (RIP)

rrMaster

Plano, Texas

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Gear ratio is 9.9:1. Headspeed around 2000 or 2100rpm. Blades are Edge FBL 710's.

I think I found where some of my extra weight is located.

Edge 710mm FBL blades: 200g/blade
Radix 710mm SB blades: 175g/blade

If I were to switch to some Radix "stick banger" blades, I would shave off 50 grams or ~1.8oz.

Flybarless blades are heavy.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-14-2011 12:00 PM  7 years agoPost 15
Ronald Thomas

rrMaster

Gainesville, Fl, USA

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They are designed to be that way for a reason

Team MikadoUSA 480XXTreme, 550SX, 600SX, 700XXTreme, 800XXTreme!!

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01-14-2011 01:57 PM  7 years agoPost 16
OICU812

rrMaster

Edson, Alberta, Canada

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Yea sbs' would not give greatest feel.

...Once upon a time there were Nitros, flybars and frequency pins...

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01-14-2011 07:47 PM  7 years agoPost 17
Jason Bell

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California

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I have been running this motor for about a week now, 10 flights about. Getting a consistant 3:30 on Flybarless. TP 45C and 65C 5000mah packs, putting in about 38-3900 mah. I expect 4min+ for various flying styles.

AMain.com
Mikado "V Team"
Xnova Motors
Optipower USA
RCProPlus

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01-14-2011 08:04 PM  7 years agoPost 18
Justin Stuart (RIP)

rrMaster

Plano, Texas

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We had some snow in Dallas, Texas two days ago which pretty much shut everything down

But today most of the snow had melted and it had warmed up to about 50F, so I pulled out my charger and got some batteries ready

I have not flown in a couple of months, but taking the Aurora out to the field was like meeting an old friend for lunch. Everything felt so right with her. While I programmed the TX timer to 3.00 minutes, decreased the pitch to +/- 85%, and lowered the headspeed to 75% just to be careful, the helicopter lifted off and shot forward like a rocket. Not a single vibration. Not a single problem. And best of all, the agility of the helicopter was like nothing else.

Flying this helicopter is a dream. For those who get frustrated with the wait and then go buy a Trex 700 or some other helicopter, you're really missing out. Perhaps it's not fair for me to say that because I've had the privilege of owning one of these machines for nearly a year now while others are still patiently waiting to get theirs, but all I can say is it's really a nice helicopter to own. For those of you who are still on the fence, it's worth the wait.

I had a crowd of 10 people at the field wanting to look at the helicopter, touch the helicopter, and take my picture with the helicopter. It was like being a rock star. No other helicopter garners this kind of attention. Perhaps they should put a warning on the box, "Danger, this helicopter is a magnet for gawkers". There is just no hiding the fact that the helicopter is really beautiful, and everyone who sees it wants to put their hands on it.

The 4525-520 Scorpion motor mated with the Jive 120HV performed flawlessly. Upon landing, the motor was just slightly warm to the touch as was the heat sink on the ESC. Now mind you, I didn't go all out 100% with the helicopter (not yet at least), and the air temperature was somewhat cold (about 50F), but I did get 3 good flights in which was enough to realize this is a really, really nice machine to fly.

I can't wait to fly it again. I'll report back my mAh usage when I recharge the batteries. Thank you to AvantRC, Scorpion Power Systems, and ThunderPower RC for making this possible.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-15-2011 10:34 PM  7 years agoPost 19
Justin Stuart (RIP)

rrMaster

Plano, Texas

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I got another 6 flights today on the airframe and the 4525 motor. At 75% throttle (which is probably about 1900HS) doing very gentle flying around (loops, rolls, big air stuff), in 4.00 minutes I pulled about 2500mAh out of the packs. The maximum I can pull from the packs (using the 80% rule) is 3500mAh.

I think this motor is actually a little bit more efficient for just "cruising around" than the 4035-500 motor. Next time I fly, I will "wring it out" a little bit more and see how she performs. I had a lot of problem with my previous Jive controller shutting off, so with this new Jive controller and with this new motor I am going to gradually work my way up to an all out 3D flight. I'm not a big fan of forced autos.

By my calculations, at 50 volts (12s lipo) this motor is pulling about 625mAh per minute. While I'm quite certain the motor is capable of pulling lots more current, it does seem surprisingly efficient with FAI style flying. The ambient temperature today was about 60F. Upon landing the motor was only slightly warm to the touch. I would estimate around 85F. By contrast with similar flights in similar weather, the 4035-500 would get much hotter.

I accidentally dropped the canopy on the concrete as I was packing things up into my car. It took a chunk out of the paint. Seems like every canopy I own has a chunk missing out of the front of it. I was just about to put the protective "canopy condom" over the canopy when it slipped out of my hands and landed nose first on the street.

But the flights were great so I am very happy.

Avant RC
Scorpion Power Systems
Thunder Power RC
Kontronik Drives

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01-15-2011 10:39 PM  7 years agoPost 20
helismash

rrKey Veteran

Gloversville, NY - Fulton

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Very, very nice!

Hey, Who put the ground there!
T-Rex 500/T-Rex 600N FBL/T-Rex 600E PRO/T-Rex 700N/T-Rex 700FBL

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HelicopterFuel-Helicopters New or Limited ActivityAvant › FBL e-Aurora w/ Scorpion HK-4525-520LE (lots of pictures)...
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