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HomeScale✈️AircraftScale HeliRoban Scale Helicopters › Roban 800 size bell 412 test mechanics, modifications, and parts
07-06-2020 11:20 PM  80 days ago
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Spookyeng

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Roban 800 size bell 412 test mechanics, modifications, and parts
Hello Guys,

I have my build thread for this posted on ScaleRCHelis, but I thought I would share some of the modifications, parts and test frame I have designed for the helicopter. I am not going to do an assembly or build, plenty of excellent threads that already cover that. Just want to share some of the ideas I have come up with along the way.

I will go on record and state, none of the things I have done are necessary for this helicopter, there are many, many models flying successfully in the stock configuration, so I would be remiss if I thought anything I am doing is required. I just like to tinker and I enjoy time in CAD, thinking of new things, designing, and fabricating parts. I am no expert by any stretch of the imagination!

I did post some of my modifications to the servo layout in the 412 thread by Droneproz, and I will add that into this discussion later, but wanted to start with the test bed for the mechanics.

I decided that since this was my first counter-rotating head and first helicopter with a four blade head, that I would design a test frame to put the mechanics in, to test and tune before installing into the scale fuselage.

Here are the first couple of pictures of where I am at now with the mechanics. I used a combination of Solidworks and Draftsight for the CAD work and my CNC router and 3D printer make these parts.

I have more to share, and I will do my best to catch up with what I have documented in the other thread on the other site in time, but at least wanted to get the conversation started.

I also want to say, I feel very fortunate to have a CNC router, laser cutter and 3D printer, and this is in no way to say "look what I have". It took me many, many years to be able to afford these tools and they have really helped with my design thoughts and obsession with design and fabrication. I just want to share and hope that it may spark some interest and if an untrained person like myself can do it, anybody can!! Talk soon guys

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07-07-2020 12:13 PM  80 days ago
cobieg

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This is interesting. Is that what the wooden structure in the doghouse looks like? And the mechanics mount to that?

Ron
I didn't crash. I just ran out of airspeed, altitude, and ideas all at the same time!
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07-07-2020 02:29 PM  80 days ago
Spookyeng

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cobieg This is interesting. Is that what the wooden structure in the doghouse looks like? And the mechanics mount to that?
Hello Ron,

Yes, that is correct. This is basically what the wooden structure looks like under the doghouse, without all the perpendicular parts that connect to the side of the fuselage. The mechanics will mount to this part. I did my best to mount the mechanics is the same area on the test bed that they are in the 412. That is the reason for the long battery/component platform foward of where the mechanics will sit. Thanks for the question and post. Talk soon.
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07-07-2020 07:54 PM  79 days ago
cobieg

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I've always been interested in that cnc and laser cutting stuff.

Ron
I didn't crash. I just ran out of airspeed, altitude, and ideas all at the same time!
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07-08-2020 04:22 AM  79 days ago
Spookyeng

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cobieg I've always been interested in that cnc and laser cutting stuff.
Me too, I remember when I got started with CAD and I used a free program called DeltaCAD and I would design the parts and then print off the design 1:1 on a sheet of paper and then 3M 77 it to the piece of wood and then with my scroll saw, files, and sanding sticks, I would create the parts. Time consuming, but there was a certain satisfaction that came from hand cutting the parts out.

Once I was able to afford my first laser cutter, it changed my world for sure. I could take a thought in my head and within an hour have parts to show for it, so it was a welcome addition. The CNC router really added a lot of capability and more materials that could be fabricated, like G10, Carbon fiber and aluminum. Now with the 3D printer, I have been able to expand into 3D and that has been another game changer for me.

Speaking of 3D printing, this is another part I am working on for the 412, a functioning oil cooler. This was well documented in the other thread and it started out as a single 30mm fan unit to what you see today with twin 40mm fans and it moves quite a bit of air and looks pretty good, much better than the screen in the stock unit and will help remove heat from the inside of the fuselage. Again, this is not needed at all, just something to add a little scale detail and functionality. After I finish the test frame for the mechanics, I will get the oil cooler mounted and I need to take a video, it sounds cool on 8.4v.

The Yeah Racing 8.4V Fans have been replaced with Scorpion 8.4V 40mm fans and I like the aluminum housing a little better of the Scorpion Units. I have had great luck with the Scorpion fan on my Tribunis ESC and within about five minutes of testing with the Yeah Racing fans one fan started to become very noisy, like a bearing was going out, so I spent the extra $7.00 on the aluminum units. Talk soon

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07-09-2020 05:05 PM  78 days ago
Spookyeng

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Progress is moving along on the test bed mechanics, just a lot of tabs to sand off and corners to square up and I only have a couple hours a day to work, but everything is fitting together nice and I should be gluing by this weekend! In the process of getting that ready, I was a the point that I had to figure out the method to mount the Futaba GY760R stabilization/RX and this is what I came up with. I am hard mounting it as they recommend in the book and there are mounting holes in accommodate. So I spend the time last night designing the mount and printing the part and this will work out great and keep the antenna at the recommended 90 degree angle. Additionally, I put the antenna on the right side to keep them as far away from the ESC as I can and I plan on mounting the ESC on the left side where most install it. The intent was to have the gyro mounted to the PETG frame and then be able to screw the assembly to the Carbon Fiber Plate, (I have to work on that tonight). It will replace the stock plate in the back. I got the 2mm carbon fiber plate in a couple weeks ago, but just getting to the point of designing the plate. More to come on that...

On the bottom picture and with the small legs, I print this on a raft so I can spread the area out and get better adhesion to the print surface and prevent warping. But with PETG, the raft sticks good, which makes removing it a little tough even at 35% top raft layer fill, but with a razor blade it comes off fairly easy, but I end up using a little sandpaper to remove any little bits I don't get with the Xacto blade. That is why the bottom looks rough, but you don't see that side anyway!

Have a good day and talk soon.

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07-09-2020 06:03 PM  78 days ago
Heli143

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Phenix City, Alabama

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Very nice work!!
I especially like the oil cooler fan system you fabricated.
Thanks for sharing!
Roy Mayoral
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07-09-2020 06:27 PM  78 days ago
Spookyeng

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Heli143 Very nice work!!
I especially like the oil cooler fan system you fabricated.
Thanks for sharing!
Thanks Roy,

I appreciate the kinds words. The oil cooler fan was a fun side project and it adds some scale detail and its functional. Not going to pull mass amounts of air, but should help keep the temps lower in the mechanics areas, which is a good thing here in Meridian, ID where it can get pretty hot. Plus it sounds pretty cool too. I will get a video up once I install into the helicopter. Talk soon and thanks again.
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07-11-2020 12:22 AM  76 days ago
Spookyeng

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Finished cleaning up all the parts and starting to fine tune fit. Everything is fitting together nicely so far with only a very minor tweak needed with a sanding stick on the sides of the tabs. Still fine tuning the offset for the cut in Vetric VCarve Pro, but I am very close to perfect fit and parts that are within .003" of being dimensional as drawn, so I am happy with the progress. I have the CNC setup to take .005" more off the cut, inside or outside respectfully and I might try .0005" more next time, but since I am not selling any parts, I don't mind having to fine tune a little bit to get a good fit. Now if the wood could have a consistent thickness from board to board, I could fine tune the thickness cutout dimension and it would be near perfect! But its wood, so I know I am asking the impossible! Moving on... I will try and break the assembly of the frame into a couple posts as I am taking a bunch of pictures.

Since the mechanics support section will need to be glued together first, I working on that part first.

I took and re-took measurements a bunch of times during the design process and I am super happy that the mounting holes and spacing between the top and bottom plate are spot on and now that I have good dimensions, I could design adapter plates for other Roban mechanics and this could be used for other models besides the 412 and 212, I don't know how many other airframes share these mechanics, but I would assume that the 412 and 212 are the same . I have my eye on a couple other models from Roban, but spoiler alert, I have been lusting over the 1/4 Bell 206B or the AS 350 from Vario and would love to build one of their kits one day, just have to save my pennies and a lot of them! I have owned the smaller 212, but sold it before I even took it out of the box. Man I am all over the map today. Back on target! :laugh:

That is all I have for now, I hope everybody has a great weekend and my goal is to get this all put together before we leave for McCall, ID on Monday. Talk soon!

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07-11-2020 06:47 PM  76 days ago
Spookyeng

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Hello Guys,

I hope all is going well. Quick update, I got the blind nuts installed and the mechanics mounting plates glued together and finished up the fit of the internal framework, so I am on track to get this done before we leave for McCall, ID on Monday. Just breaking it up, since I am taking a lot of pictures. Mainly to document and I take a bunch of photos in case I need to reference them in the future. I don't post half of them!

I used a little Hysol 9462 on each blind nut before pressing into the wood.

I use my drill press and three 1-2-3 block to press in the blind nuts

Next up is to install the plates to the upper and lower mechanics mount. I am a big fan of Vogelsang Aeroscale Aerobond express, sets up fast and dries clear for a nice clean look after gluing and super strong joints. I use it for 90% of my wood gluing and the other 10% I will use Hysol for critical areas like motor mounts and anytime I am bonding composite or metal to wood.

It was certainly convenient that the mechanics blind nuts passed through the wood, as it helped line up the plates to the mounts!

Clamped up and then another dry fit!

First time trying to paste up and have the pictures in order with a comments, instead of pasting them down, thanks Mark for the tutorial. I think it will better flow with the pictures in the post. Let me know what you guys think? I still like how you can click on one and then scroll through all of them at one time. More to come later today. Talk soon
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07-12-2020 05:55 AM  75 days ago
Spookyeng

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So I have finished dry fit and the test frame has been glued together and I am happy with the results. Its always nice to see, what was once a thought in your head a couple of months ago to physical object is rewarding. Still a lot to learn and improve upon, but this was a fun project and I am happy with the results so far,

Here are a couple of pictures of the final dry fitting before gluing together. I left the right side frame out to show the complete internal structue.

Final picture before gluing the bottom plate it, all other parts had been glued together by this point and I spared you the other 20 photos I took during these steps.

Here are the final pictures of the unit completely glued and ready to start installing the mechanics

]

Picture of where I would expect to mount the components in the test frame, but always open to constructive inputs and suggestions

Up next is to get the aluminum tubing bent to shape in the front and secure the tubing to the landing gear legs. I plan to work on that tomorrow. More to come, thanks and talk soon.
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07-13-2020 12:11 AM  74 days ago
Spookyeng

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I did finish up the landing gear today and I will need to order up some longer 3mm screws, but I will do that tonight and I will have them by the time we get back from McCall on Thursday. Our local supply store only had 3 x 30mm socket head cap screws and I need 35mm.

Started with cutting off 5" from each tube and then bending the front of each tube. I did 45 degrees and think they look OK, but I think 30 degrees would look a little better, but let me know what you guys think?

Next up was to get the gear in the right position and then drill the holes for the mounting screws. I did use 1-2-3 block again to make sure the gear bend was perpendicular to the ground. To note, I drilled through one side and put a small bolt in each landing gear leg and then drilled the other side to make sure the holes were straight thru.

Pulled the tubing out to clean up the holes and remove any metal shavings

Then assembled the gear back together and everything fits good and aligns up well. I will final install once I get the 35mm cap screws in.

That essentially completes the test frame for the mechanics and I am happy with the results. When I get back from vacation, I will go through the mechanics and get the gyro mount plate designed and cut. Talk soon.
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07-18-2020 02:11 AM  69 days ago
Spookyeng

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Started to disassemble the mechanics, I want to go through everything and check all the components over. it would be awesome if you had the option to buy the mechanics in kit form and assemble them yourself. Just want to make sure all rotating components are balanced and running true along with thread locker on all the metal to metal contact screws. I also will work on the plate for the gyro mount and start the process of re-assembly. I hope all is well and have a great weekend. Talk soon.

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07-18-2020 05:44 AM  69 days ago
Heli143

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Phenix City, Alabama

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Thanks for the updates!!

Once this coronacrap is over we can all get back to enjoying our hobby😎
Roy Mayoral
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07-19-2020 03:25 AM  68 days ago
Spookyeng

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Heli143 Thanks for the updates!!

Once this coronacrap is over we can all get back to enjoying our hobby😎
Thanks, I hope you guys are finding the posts useful, I know I am enjoying assembling the helicopter and sharing a few of the things I am working on.

Update from today. Been working on the frame parts and checking the balance of the rotating components. So far, the components are fairly well balanced, the main gear and 78T Belt pulley with the one way bearing will need just a little bit to get them in perfect balance. I may try and turn the hub on the main gear in 180 and 90 degree orientations to see if I can get it to balance without adding or removing any weight. I will of course take weight figures before and after for reference, I don't think its going to need much, but they both have a heavy side and that will need to be corrected before flying.

I spent the time today to design the new plate for the gyro mount and this was cut out of 2mm carbon fiber, Here you can see the stock plate on the right and the new plate on the left.

The gyro and mount are attached to the Carbon Fiber plate with 3 x 14mm socket head cap screws and nylon lock nuts.

Took a few moments to check clearance inside the fuselage and everything looks good. It is plenty far away from the oil cooler fans, so we can check this off the list of things that I needed to get done.

That is all I have got done with my couple of hours in the garage today, I hope everybody is having a great weekend. Talk soon.
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