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HelicopterScale Model RC Helicopters Docs  Airwolf Turbine - My Build
03-13-2016 03:03 AM  19 months agoPost 261
ssmith512

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Indianapolis, IN USA

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Can I get a WHOOP!!! WHOOP!!!

Busted my butt today and managed to get in some quality time with The Lady.

Decided Wolfie needed pitot tubes and an in-air refueling probe. Still working on the refueling probe (will show that tomorrow), but here is the pitot tube construction. Brass tube with a stainless steel rod full length in the tube. Nice and solid, no chance for it bending or being dented from hanger rash or transport damage. Turned out pretty decent......

Onto the rear defense pods (chaff and flares). OK, most of you I know think I am a tad bit crazy, well, I am leaving no doubt that I am certifiably insane. I think I managed to develop the most difficult method for fabbing these pods. Lots of holes that need to line up and be very uniform in size and spacing. My cheap drill press just wasnt up to the task. Drill bit kept walking off center and the holes just looked like crap. So, I came up with this...............
Started with a bunch of styrene tubes and strips......

Began gluing them into a matrix. This matrix will become the flare tubes.......

Plugged the exposed tube ends with clay....

Then fabbed a balsa dam and placed the tube matrix in place. Clay plugged ends are facing down....

Mixed up and poured in resin.......

Once the resin dried, I popped them out. I now have a rear defense pod with consistent and uniformly spaced holes/tubes. Ready for shaping....

Used the mini belt sander and sanded the face flat and smooth and to expose the clay plugged ends....

Trimmed and sanded........

Added the surrounds and sanded to shape....

And for poops and laughs, temporarily stuck one in place just to see what it will look like.......

Not too shabby! All I need is a little more detailing work, and a little paint and I think I will be happy with the result.

Tryin to keep it real

Steve

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03-13-2016 03:08 AM  19 months agoPost 262
Copter Doctor

rrProfessor

Enterprise/ft.rucker ,al- home of army aviation

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SWEEEETNESS!!!!!!

drive a rotary, fly a rotorcraft

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03-20-2016 07:55 PM  19 months agoPost 263
ssmith512

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Indianapolis, IN USA

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Not much accomplished recently and unfortunately work on the Wolf will slow to a crawl. Building a new house and getting the current house ready to put on the market will be taking up most of my "hobby" time - coupled with the fact that the room I am using to work on the Wolf needs cleared out for new paint and carpet - so I am losing my "workshop". UGH!!

Oh well, I am getting a pretty decent work area all to myself at the new house, so I cant complain too much!

Glued the horizontal stab winglets on. The screw head is recessed and will be filled in....

And worked on the rear defense doors. A little movie of them in action......

Watch at YouTube

Turned out pretty good. Lots of detailing still to do on them, but the concept has proven to be sound and works as intended. I may speed up the opening sequence. They pop open pretty quickly when watching the TV series.

Not much left to before we start shooting primer. Cant decide if I want to shoot primer before or after I cut out the window and door openings. Any advice from the scale masters??

Steve

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03-20-2016 08:14 PM  19 months agoPost 264
Notar

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Taxachussetts

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Cut out windows first.
Joe

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03-20-2016 08:44 PM  19 months agoPost 265
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Cut out windows first.

Watch at YouTube

Steve

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03-27-2016 01:39 AM  19 months agoPost 266
ssmith512

rrKey Veteran

Indianapolis, IN USA

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OK, cutting out window and door openings is time consuming thing. But we got them all cut out and they look nice. Edges turned out straight and smooth.

Started with doing some layout and used tape for a guide........

And after cutting, filing and sanding, the finished product......

Very happy with the result. Edges turned out straight and smooth.

Starting to look like a helicopter! List of bodywork to-do list is getting shorter and shorter and priming day is not far off.

Steve

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05-24-2016 06:18 AM  17 months agoPost 267
Dingo07

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Newport Coast, CA - USA

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Where are we at with this behemoth!!?!? Any more progress after the move?

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05-24-2016 12:05 PM  17 months agoPost 268
Heli143

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Phenix City, AL

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Steve saw the IRCHA 2015 DVD and you flew your Cobra.
The Cobra looks fantastic, can't wait to see it in person.
And your flying was awesome!!

Roy Mayoral

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05-24-2016 04:23 PM  17 months agoPost 269
ssmith512

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Indianapolis, IN USA

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Thanks Roy! Cobra is my favorite flier right now.

Dingo07 - nothing has happened the past 8 weeks. All my heli related stuff has been packed away in storage in preparation of selling the old the house. Old house has sold and we are now just waiting for the new house to be completed. It is scheduled to be complete mid June. Then move in, get situated, then finish my new work space, then I can get back to working on my heli's. Probably realistically looking at early to mid July before that happens. My hope is to get Wolfie back to flying condition (unprimed) so I can get it to IRCHA in early August and do some flying with it. Then after IRCHA I can go full speed with finishing it.

Here she sits patiently waiting to be moved out of storage.....

Steve

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07-04-2016 01:24 AM  15 months agoPost 270
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Hello Everyone!!!!

Long time lurker, first time posting in the scale section LOL!

SLOWLY, but surely getting the new workspace up and running. Getting situated in the new house has been more time consuming than I had anticipated and coupled with being very busy at work, the two have completed isolated me from my heli's for far too long. I have light, ample power and Ipod tunes in the new "workshop", so off to a good start. Still have some unpacking and organizing of the new workspace, but with luck, should be back to doing some actual work on The Lady soon.

Will get her back to flying condition and ready for IRCHA next month. I have a new Vario rotor head to build and try while at IRCHA.

Till then,.........

Steve

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07-04-2016 02:08 AM  15 months agoPost 271
CoachE

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Cincinnati, ohio -usa

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Team JR / Get !T - Got !T - Perfect !T

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07-04-2016 02:11 AM  15 months agoPost 272
Mojave

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Palos Verdes, Ca. USA

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Well, it's about time... Helis is looking good and the shop is nice. I have all of my stuff packed away too, our house hits the market Tuesday. I'm having heli withdrawals...
Barry

All helis and planes have an expiration date stamped on them...you only find it after you crash!!

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07-06-2016 01:22 AM  15 months agoPost 273
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Barry,

I know all about the heli withdrawls. I havent flown squat since last year before winter. I have a new TX that has been its box since February.

The nice thing about unpacking though is I am finding some heli stuff I didnt even knew I had (or at least forgot I had! LOL!).

Looking forward to "getting at it" again.

Steve

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07-06-2016 01:55 AM  15 months agoPost 274
Copter Doctor

rrProfessor

Enterprise/ft.rucker ,al- home of army aviation

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in the 30+ years I have been flying rc I don't think I have ever taken a break, not even for a week, I would die. a weekend is about as long as I can go without my vital organs shutting down lol! glad you are getting back at it soon, we don't want to lose you

drive a rotary, fly a rotorcraft

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07-06-2016 01:10 PM  15 months agoPost 275
ssmith512

rrKey Veteran

Indianapolis, IN USA

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we don't want to lose you
You didnt get the memo?

For better or worse (probably worse) you are stuck with me!

Steve

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07-09-2016 05:42 AM  15 months agoPost 276
Dingo07

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Newport Coast, CA - USA

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Happy to see the fire still burning!

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07-10-2016 02:07 AM  15 months agoPost 277
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Embers needed a little fanning, but we got the flames roaring again!

The Lady was lonely and needed some well deserved attention, so we decided to give her some TLC.

First on the list,...the nose guard thingy.
Positioning for alignment.....

And fitted with #1 screws. Sure is purty!...

Next up, the left engine cover inlet guard. Started by shaping some styrene sheet into a semi tube shape by wrapping around in properly sized aluminum tube and then heating the styrene with the heat gun. Once it cooled, it maintained the tube form....

Then glued in place. Just needs a little filling and final shaping....

Steve

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07-10-2016 02:22 AM  15 months agoPost 278
ssmith512

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Indianapolis, IN USA

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Now on to the main gear wheel wheels. Layed out and rough cut started.....

After several minutes of filing and sanding, ended up with some nicely shaped wheel well openings....

And of course permanently glued the winglets in place and bondo'd the seams for a nice smooth transition...


And to finish out the day we finalized the turbine exhaust outlets. This was a bit challenging for me due to the need to create an ellipse from the round exhaust tubing. Started with a cardboard template to help me with marking straight lines and getting the angles and shape correct....

Used some pinstripe tape to mark out the cut lines.....

Then using a combination of aviation type shears, dremel, flat jaw pliers and compound file, managed to not screw up and got the outlets looking pretty good (at least I think they turned out OK)....




Feels good to be back on the horse again. Building a new Vario rotor head. Gotta fabricate some blade spacers and reprogram the Demon. Working on getting her ready to fly at IRCHA in a few weeks.

Later!

Steve

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07-18-2016 01:13 AM  15 months agoPost 279
ssmith512

rrKey Veteran

Indianapolis, IN USA

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IRCHA Preparation Step 2 is complete. Vario rotor head built and mounted. It required new control geometry and some blade bolt "modifications".

The geometry of the Vario head required some new longer servo arms to achieve the required throws and pitch settings with the Demon FBL. Found some Seacraft arms the correct length at my goto online retailer esprittech.com and ordered them up. The Seacraft arms are tapped for M2 thread, but my servo balls are M3 so I drilled and tapped for the correct thread......

The Vario head is setup with 6mm blade bolts and the grips are spaced for a 22mm blade root thickness. My main blades (both Viper-X and M-blades) use a 5mm blade bolt and are 14mm thick. So I had so fabricating to do. I fabricated some brass spacers to space out the 6mm blade bolt hole in the Vario head so I can use 5mm bolts. I also got some 4mm thick aluminum bar and made some blade spacers....

Here is the new head mounted and ready to go. This thing is a beast!!.....

And some pics of the "body-in-white" for the fun of it.....



And finally a systems check. Jakadofsky is the shiznit. Been sitting for 8 1/2 months and she fired right up on the first try. Didnt miss a beat. Warning the next 5 minutes is pure excitement!!!

Watch at YouTube

So far so good. Gotta a few small things left to do and I should be ready for some test flying at IRCHA.

Steve

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08-13-2016 05:32 PM  14 months agoPost 280
ssmith512

rrKey Veteran

Indianapolis, IN USA

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Welp another IRCHA has come and gone. What great time it was!!!

Flew Airwolf a few times on Saturday. First flight was uneventful, although the wind coming from the right was giving me fits, especially on the down wind leg of a turn. Just had trouble staying ahead of the heli control wise all day. Downwind she would loose altitude QUICKLY! Anyway, sorry the quality on this video is super sucky - used my phone which doesnt have a memory card in it so the resolution is circa 1983 Super 8 quality.......

Watch at YouTube

Next flight I had an issue with a festo fitting and the turbine was sucking air and started overheating and started loosing power. I heard it, and was able to get the gear down before she started falling out of the sky. I was facing downwind when it happened. I as at full collective (11.5 degrees) when she touched down. Landed a little harder than I would have liked, but fortunately no damage......

Watch at YouTube

Fixed the festo fitting issue and for the last flight, I made some changes to the Demon, mainly increasing elevator filter settings and upped the total head gain from 65% to 75%. Wind was pretty breezy from my right. The heli started sliding off to the left and loosing altitude. I would swear that I was giving right aileron and collective, but the heli didnt seem to respond. I thought I had lost radio control of the aircraft and hit throttle hold. Just before impact you can see the heli rotate to the right - just like it should if I were inputting right aileron and thottle hold engaged - which kills the turbine - so I obviously had radio control. Fortunately she hit terra firma fairly straight and not sliding sideways too much......

Watch at YouTube

What happened? I honestly dont know. But I am going to chalk it up as pilot error - plain and simple. I was having trouble with the wind all day - just not used to flying a 40lb heli, and I dont think I was giving enough control input all day long. Probably too scared to get too much input into the heli. I think a small gust of wind came from the right, and I dont think I ever gave enough contol input to counter it. I think I may have "froze" on the sticks. By the time the heli actually responded to my input, I had already hit throttle hold so I had no power to "pull out of it" when I realized I still had control. I have no other explanation for what happened.

Post crash inspection so far has revealed 3 sheared bolts on all three gears. Nothing was bent, so I extracted the three bolts, replaced with new and the gear all works perfectly fine again. I have a few broken glue joints on some wood formers inside the fuse and few hairline cracks in the gel coat on the exterior. Simple and very easy fixes. Either I got lucky or I can build a beast of a helicopter. I am going to go with I got lucky - REAL lucky! But all in all, I got away with one and I owe the heli Gods for sure. Should be ready for Dalton unless I find something else. Then after Dalton, if everything goes well, we start full speed on exterior detailing and getting her ready for paint!

Steve

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