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Joker › Joker 500th flight tear down (maintenance tips)
05-06-2005 04:06 AM  13 years agoPost 1
tabbytabb

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seattle

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Well guys I had my 500th flight on my Joker CX this last week so I figured it was time to tear her down and do a complete inspection. Here are some of the things that I found were worn, or getting worn. The list is short as you would expect with such high quality components

First off was the actro adapter shaft. see here:

As you can see where the shaft contacts the inner race it has worn down the shaft considerably and allows the actro to woble around and creatw an inconsistent gear mesh.

The next issue was that the tail box bearings had become sloppy in the tail box. I remedied this by loctiting them back in with some green loctite.

When i originally built this puppy I loctited every shaft to the inner race of whatever bearing it goes through and I think this helped with the amazing longevity.

The next issue was that all 3 gears were worn down some. I swapped them out for new ones since the teeth were showing some Asymmetry and it isnt worth the risk with all the camera gear and load it imparts.

This was about all I had to replace. I gave her all new electronics and polished up the head a bit to remove some of the seattle corrosion.


Needless to say I hope the next 500 go as smoothly as these did!

Thanks Gerd for building such a trouble free machine!

Tabb

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05-06-2005 04:37 AM  13 years agoPost 2
lowandslow

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Spring Hill, TN

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Not bad at all I'd say. If I can get that out of my ION, I'd be pretty happy.

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05-06-2005 05:31 AM  13 years agoPost 3
bell-230

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sonoma, ca (currently milano italy)

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these german helis sure are built great!

and thats quite a bit of wear there on the shaft!

ian brooke
k2shots.com

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05-06-2005 06:59 AM  13 years agoPost 4
Dakine

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OC, Commifornia

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That is AWESOME Tabb!!! Thanks for sharing.

Were all 500 flights flown with the same batt. packs? LiPo's?

What do you log after each flight, if any?

I'll post some pictures Mr. McNair had emailed as added tips as well.

When I reach my 500th flight, in ten years, perhaps I may send my Jokers to Tabb's German Heli Specialist Shop for a complete overhaul?

Thanks again.

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05-06-2005 07:09 AM  13 years agoPost 5
tabbytabb

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seattle

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yep, all 500 on the same set of TP Gen 2 5s4p packs.

The thing is I usually discharge only around 4000mah and recharge at .5C so I think this has aided the longevity of the packs. I need to cycle them to see what kind of capacity I am getting at this point.

After a flight, or day I flying I just make note of how many flights and rough flight time. Just so I have an idea when it is time to change components.

Tony, I will take a pic of my "shop" tommorow A smart man would know better then to send a heli to my shop!

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05-06-2005 08:17 AM  13 years agoPost 6
rroback

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Irvine (UCI), Ca

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Wonderful. I wish I could get 10 flights at a time with my joker before I plow it into the ground :P just shows, lipo's do work, given you start with a good pack, and you're responsible and never over discharge. I've never had a pack fail, but I usually destroy them before i'd be able to see any changes...

r

Rhett..... I can't fly, but the Profi sure can.

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05-06-2005 12:07 PM  13 years agoPost 7
Gerd

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Vellmar/Germany

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Annotation: The shaft seen here is the old non-hardened version. Since autumn 2003 they are hardened on the full length.

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05-06-2005 01:27 PM  13 years agoPost 8
daveye

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North Carolina

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Thanks Tabb, very useful information.

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05-06-2005 01:59 PM  13 years agoPost 9
HUTCH964

rrKey Veteran

Taylor,Texas 76574 local airport T74

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Tabb Thanks...
This just might push me over the edge to add a Joker CX to my Fleet!!!!

That is Great!!! Very Good Post

.

Tim

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05-06-2005 03:03 PM  13 years agoPost 10
GMcNair

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Birmingham AL

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Thanks for the info Tabb, good stuff.

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05-06-2005 04:15 PM  13 years agoPost 11
tabbytabb

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seattle

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Thanks guys

Gerd, I ordered a new shaft and the one I received has the flat spot filed in the wrong location. Is it meant for the 32-x series motor?

I just filed a new one and it seems to work fine, I was just wondering.


Tabb

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05-06-2005 04:42 PM  13 years agoPost 12
jeffscholl

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Whitefish, MT

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Nice post Tabb,

Confidence through reliablity is what it comes down to when you spool these ships up every day.

Cheers,
Jeff Scholl
GravityShots.com

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05-06-2005 04:56 PM  13 years agoPost 13
sailmike

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Northridge, California, USA

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Yeah, thanks for the info Tabb. EVERYTHING from Germany always seems to be well made.

Mike

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05-06-2005 10:40 PM  13 years agoPost 14
Gerd

rrVeteran

Vellmar/Germany

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I must concede that there is no documentation about this part, so here is a pic of the built-in-situation of the hardened shaft:

There is a fillet now between the 5 mm shaft and the flange part for more stiffness. We have made a bush with 10.5 mm length and a big inner chamfer as adaptor, then everything is fitting like before. Of course the side with the chamfer must show to the fillet.
These bush was added to each hardened flange. Fits also with 32-actros.

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05-08-2005 11:26 PM  13 years agoPost 15
ThomasJoehnk

rrApprentice

Denmark, Copenhagen

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Hi

I will also admit that the Joker is ***very*** durable. On my Joker CX I now have a little more than 100 logged flights with either a GP3300 or GP3700 pack. Every flight on these packs last between 8 and 12 minutes. Futhermore I have an uncounted/unlogged number (propably 100+) of flights on two old NiCd 2400 packs.

My Joker was bought secondhand from ebay.de and until now I have not spend a single penny on spare parts on this bird!

In terms of price/flight this heli has been much cheaper than my Logo 10 or my Hornet 2 (now sold).


Thomas



Minicopter 3D and 3DD, TDR, TRex 700E (and a full size 90.000 cubic foot hot air balloon)

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05-09-2005 12:09 AM  13 years agoPost 16
tabbytabb

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seattle

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Gerd, thanks very much for the pictures. I now see what I did wrong. I assembled my adapter as it was previously without any spacers. I will fix it up tonight.

Can you explain which part you are talking about when you refer to the "fillet"

Thanks!

Tabb

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05-09-2005 09:10 AM  13 years agoPost 17
Gerd

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Vellmar/Germany

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Hi Tabb,

I mean the zone on the flanged shaft where the 5 mm shaft part hits the 23 mm flange part. If there is no fillet (a radius of 1mm), the risk of break from vibrations and bending is very high.

Gerd

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