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03-31-2018 04:18 PM  7 months agoPost 41
garyl

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After I had the swash plates made I want to test out the geometry and make sure everything is going to work.

I designed a prototype fixture to test it all out.

Good thing I went through this exercise because I learned where I actually had to put the anti rotation device, 90 degrees from where I assumed it should be.

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03-31-2018 04:47 PM  7 months agoPost 42
garyl

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Here is a video of the working test fixture.

Watch at YouTube

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03-31-2018 08:02 PM  7 months agoPost 43
Pistol Pete

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Wow...nice.

Seems the left assembly "pitch" is faster than the right.

Maybe the camera angle?

~~Enjoying the hobby one flight at a time~~

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03-31-2018 09:41 PM  7 months agoPost 44
garyl

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There is an adjustment for that in the software. It will all be adjusted later when the mechanics are finished.

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04-15-2018 09:32 PM  7 months agoPost 45
garyl

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I finalized the mechanics design for the control servo layout and side frame spacers.

Finished making the side frame spacers today out of 6061 aluminum. The main shaft bearings fit perfectly

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04-16-2018 04:27 AM  7 months agoPost 46
Mojave

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Nice design work and machining!
Barry

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

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04-16-2018 11:51 AM  7 months agoPost 47
garyl

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Thanks Barry! When I was in trade school the CNC machines were programmed using punch tape, LOL. Fusion 360 has great CAM software with all the post processors for a ton of machines and machine software. I just recently upgraded the stepper drivers and switched from Linux CNC to Mach 3, its so much better.

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04-16-2018 03:50 PM  7 months agoPost 48
GyroFreak

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garyl
were programmed using punch tape,
My early computer programing was paper tape or punched cards in the distant far far past.
Really impressive work you are doing here, I am learning new stuff from you, thanks for al the detailed drawings and vids.
Hope to follow this to a successful flight.

I think about the hereafter. I go somewhere to get something, then wonder what I'm here after ?

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04-17-2018 11:39 AM  7 months agoPost 49
garyl

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Thanks, its has been a big learning experience for me as well. I haven't touched a mill, let me say in a very long long time let alone a CNC.

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04-18-2018 02:07 PM  7 months agoPost 50
JurassicJet

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WI

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This is an awesome build. I really like your ability to innovate and implement your CNC machine into building the mechanics. I have a large vertical mill that I am thinking about converting to CNC and your posts have pushed me closer to pulling the trigger on that project.

I have always been impressed with the Kaman helicopters. True workhorses. I talked to a pilot out in Aspen, CO one day when I was waiting for my pax to show up, and it was very impressive what that heli could do. He was setting some sort of a communication antenna on top of one of the nearby mountains.

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05-04-2018 09:28 PM  6 months agoPost 51
garyl

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JurassicJet
This is an awesome build. I really like your ability to innovate and implement your CNC machine into building the mechanics. I have a large vertical mill that I am thinking about converting to CNC and your posts have pushed me closer to pulling the trigger on that project.

I have always been impressed with the Kaman helicopters. True workhorses. I talked to a pilot out in Aspen, CO one day when I was waiting for my pax to show up, and it was very impressive what that heli could do. He was setting some sort of a communication antenna on top of one of the nearby mountains.
Thanks, Nice to have a large mill but the cost to convert it to CNC will be costly.

I just received the side frames I had cut at http://www.cncmadness.com/ and he did a great job!

All the parts shown in the photo are 3.5mm thick carbon fiber and only cost $74 shipped. Now the assembly fun begins.

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05-14-2018 01:17 AM  6 months agoPost 52
garyl

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Started the mechanics assembly, cut the gear shafts and cut a flat for the set gear set screws. The important part is getting them aligned for proper rotor head 90 degree alignment. I ended up using SAB HPS2 rotor heads which have independent hinged blade grip spindles. This allows for independent blade flapping which is good for intermeshing rotor systems.

This is a Trex700 main gear with the one way bearing hub on a 12mm shaft.

I used thrust bearings mounted between the side frame to secure everything in place.

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05-14-2018 01:33 AM  6 months agoPost 53
garyl

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Since these gears will be hanging outside the mechanics I designed this gear cover for a few reasons, I did not want anything to get chewed through them and to stop gear grease from slinging out everywhere. I printed it using PETG material.

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05-14-2018 01:50 AM  6 months agoPost 54
ssmith512

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Indianapolis, IN USA

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Wow! The craftsmanship so far is off the charts. NICE work Gary. Cant wait to see it up close.

Steve

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05-14-2018 05:04 AM  6 months agoPost 55
Heliguychris

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Perth, West Australia

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I really enjoy youre posts with the pix, thanks for taking the time to share with us.

Licensed (CASA) UAV operator certificate holder 1-YFOF5-01 www.helicamaerial.com.au

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05-15-2018 04:24 AM  6 months agoPost 56
HilliHeli

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S.MI./FL.

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Subscribed

!Antriebe, die bewegen!
Henseleit-Helicopters.de
Jazz', Jives & vbar's
Futaba FASST / FASSTest

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05-16-2018 04:17 AM  6 months agoPost 57
Mojave

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Palos Verdes, Ca. USA

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Absolutely pro fab work there! I really like the 3D printed gear cover too. I'm really looking forward to your first flight with this heli.
Barry

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

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05-16-2018 11:43 AM  6 months agoPost 58
garyl

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Thanks all, it keeps my mind occupied for sure.

I printed a silhouette of the fuselage where the mechanics will fit and as you can see its very tight.

The one thing I am worried about is the amount of unsupported main-shaft above the top bearing blocks, this could end up causing bent main shafts under the full load of the finished fuselage. Gradually adding weights will be part of the flight test program.

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05-17-2018 07:14 AM  6 months agoPost 59
Mojave

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Gary, I agree. That's way too much unsupported shaft. But, that issue is easily remedied with a tall bearing support like the Lama or R22 uses. Start drawing it up...
Barry

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

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05-17-2018 11:55 AM  6 months agoPost 60
garyl

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Barry, The main reason you don't see a production model of this is because there is simply no room for anything to fit properly and still be scale. If I install the main shaft support the swash plate will have to be above it and there is no room for it, see the photo. As it is now I have to modify the fuselage from the proper scale shape to make what I have fit. If I have main shaft bending issues this project may end at the mechanics test phase.

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