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HomeScale✈️AircraftScale HeliScale Helicopter Main Discussion › retractable light on belly of hughes 500
06-06-2011 01:16 AM  8 years ago
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James

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Del Mar California

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retractable light on belly of hughes 500
can anyone give me some tips how to make this housing part, or were i can have one made for me. I do know were to get the light.
would be much apreciated

Jim

flying is the easy part paying for it whole different story
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06-06-2011 02:30 AM  8 years ago
Christopher J

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Make the shape out of balsa and find someone with a vacu-form table and mold it.Christopher J
same as I ever was
"Still all set & Flying the original"
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06-06-2011 02:50 AM  8 years ago
Mojave

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Good idea. Or option #2 is to have the male/female parts made on a 3D printer, then hinge them. There's some info regarding this in the AS350 build thread, Page 9.

https://rc.runryder.com/t618483p9/?p=5343435#RR
All helis and planes have an expiration date stamped on them...you only find it after you crash!!
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06-06-2011 05:32 AM  8 years ago
seattle_helo

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Hi Jim. You may recall a few years back we discussed this a little bit here:

https://rc.runryder.com/t523695p1/

But the basic construction is this:

1) Totally disassemble the Heli-Factory light.
2) Using only the lamp portion as a reference size out the rough pieces of balsa for the plug. The full size Grimes light is just a stamped aluminum housing. Vacu-formed plastic is the perfect way to replicate it.
3) Create two pieces to make the clam-shell type housing. Shape them and also be sure to make one piece slightly wider at the base where it will 'plug into' the other piece. I did this by making identical sized wood pieces and then I wrapped the bottom carefully with a strip of 1x5mm styrene.
4) I had my good friend, Joe Howard, make the vacuum formed pieces from the balsa plugs.
5) Cut them out carefully and fill/sand any imperfections.
6) I modified the Heli-Factory retract mechanism to fit. That involved cutting it apart, removing some of it and JB welding together other parts of the frame. I totally removed the direct servo drive as there is, of course, no room for it in the pod. Create an arm out of music wire or a pushrod that can extend up into the fuse that will allow the lamp to extend & retract.
7) Trial fit this into your pod. This is where you'll need to make small changes and optimize the fit as needed. You want the cutout around the lamp to be very close to the edge of the lamp itself and you want the whole thing flush when retracted. You may need to sand down the mounting posts (just a little) from the Heli-Factory frame to get it flush.
8) I used four 2.5mm bolts to attach the top of the pod to the fuse. Use some relatively large fender washers on these to help distribute the load so it does not crimp the plastic pod piece. Create your holes and the slot for the mechanism arm to extend through.
9) Fit everything and operate it by hand. Check that nothing binds and that the pod is not deformed when you tighten it up to the fuse and then attach the lower "shell" to the top. Connect your servo and carefully set your throws so that the lamp extends and retracts to the correct positions.
10) I added a micro-switch so that the lamp switched on automatically at the end of it's travel.
11) Once it's all smooth and operating properly take it all apart and paint it. I used some clear canopy glue mixed with silver acrylic paint to make the rivets on the lip where the two halves join.

The whole thing works pretty good. If you drive the 1W Luxeon at full power it's pretty darn bright, too.

video of extend/retract (.mov file)
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06-06-2011 05:49 AM  8 years ago
James

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Hi Nick

I am so impressed in how you made it it's a work of art. I can see it was a lot of time in building, im glad i have lots of patience like you because im going to need it to build it. I first need to find some one with a vacuum machine for plastics. I have a good start up plan you have posted very clear instructions. Also the video is just incredible to see the light funtioning it's very smooth.

thank you for this help

Jim

PS i am curious how long did it take you to build it.
flying is the easy part paying for it whole different story
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06-06-2011 06:09 AM  8 years ago
James

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Hi Mojave your idea is also very good i have some good choices how to approach it 3D printing that would be different the link you sent me i was impressedflying is the easy part paying for it whole different story
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06-06-2011 06:13 AM  8 years ago
James

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Del Mar California

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christopher

i think making a plug from balsa wood it gives me a good start to get the shape in perspective

thanks for the tips

Jim
flying is the easy part paying for it whole different story
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06-06-2011 06:21 AM  8 years ago
seattle_helo

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Jim, as best I remember the whole assembly took about a month of on and off again work. Assuming you have the light assembly and vac-formed pieces on hand you could do it much more quickly if you focus on it. My problem is that I don't focus....
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06-09-2011 04:33 AM  8 years ago
James

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Del Mar California

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Hi everyone check this place out shapeways.com can make custom parts for your helicopter to great accuracy the parts are 3D printing and i found a place from a good friend in England Mike Pattison, which also has built a vario size G-Jive like mine his is a turbine were mine is gas.
Well this place is great there is so many things i can get made to order or already built, displayed on there site shapeways.com The good part is custom part's to made to what ever your needs are for your project.

Here is a direct link below to the parts. I got for my G Jive windows, collectives, my bottom light case, tail control peddles, you name it great place and affordable prices. Thanks to to Mike, P. he helped me out with these custom parts. They are made in many different types of materials the customer chooses what they need. Here are some pictures of them already installed so you can get a idea of the finshed product.

For any reason you ever want to purchase these parts down the road and the link does not work, just pm me i will take care of it for you so you can see the parts.

enjoy i have

http://www.shapeways.com/shops/scaleparts

soon there will be two G Jive's that look very a like

flying is the easy part paying for it whole different story
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06-10-2011 10:01 PM  8 years ago
SSMKN2

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Trenton, IL

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I didn't have to build the housing due to mine being on a Huey, however, I used the backpiece from an old mini maglite flashlight, and then the clear piece from the front cut down....and then you can engineer the rest if it from balsa as stated earlier. There are a number of ways to accomplish this, good luck on whatever you choose.Joel
MD 500D
Bell 206
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06-11-2011 01:42 AM  8 years ago
James

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Del Mar California

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Hi Joel,

using a mag lite for the light good idea something else to consider thank you on those tips every little bit helps

Jim
flying is the easy part paying for it whole different story
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06-11-2011 06:52 AM  8 years ago
seattle_helo

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Seattle, WA USA

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Jim, here's a few photos of the full size in case they may be of help. Notice the thin shell of the housing and that it also tapers toward the back.

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06-12-2011 06:17 PM  8 years ago
James

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Del Mar California

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oh my great pictures indeed seeing the real thing that is a monster of a light plus looks very powerful with that holagen light bulb inside. makes you really apreciate the light when you see it full size

thanks for posted these pictures its very helpful

Jim
flying is the easy part paying for it whole different story
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06-12-2011 06:36 PM  8 years ago
James

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here are more pictures of what the completed parts look like once painted and installed on Mikes P. G-Jive in england

flying is the easy part paying for it whole different story
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06-13-2011 12:09 AM  8 years ago
WrenFlyer

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Mississippi

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This would be a good starting point for your lamp assembly.

http://www.scaleflying.com/White-La...Leads_p_19.html

It's what I used for my searchlight on my AS-350 build.
Mr. Haney
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06-13-2011 12:17 AM  8 years ago
WrenFlyer

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Mississippi

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Here's a deal, I would like this light for my AS-350 (Without the housing) and the UH-72A that I build at work has the same light...I'll get some measurements and have my son draw it up in Solidworks. Mr. Haney
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06-13-2011 07:08 PM  8 years ago
James

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Del Mar California

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Hi Alan thank you for this help. The light looks good like to see what your son draws up this is great!

Jim
flying is the easy part paying for it whole different story
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