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0| v22chap
rrKey Veteran Granger, Indiana |
Rebuild of 2004 scratch built V-22 tilt rotor I have been wanting to do this for about 17 yrs now !!!
I have wanted to rebuild my 2004 crashed scratch built V-22 . It did a nose first lawn dart stall from about 75' up trying a full conversion to airplane mode and hit the right nacelle and nose . 
I have most of the fuse and the wing is complete .. I have some gears left from a couple guai 425's when I did the Puffin for the NASA guy ,, and I have an older style Rotormast v-22 flight controller that still works ..and I have talked with Tom about his little FC doing a bigger bird like this and he says YES DO IT !!!I am really getting bogged down with doing scale cockpit and painting ... I need some balsa dust up my nose and glue on my fingers !!!! ARRRRRRRGGGG  Now that I have pulled this out , and got a fresh look at it ,,,,,, maybe I have bit off more than i can chew     |
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 Copter Doctor
rrProfessor Enterprise/ft.rucker ,al- home of army aviation |
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| v22chap
rrKey Veteran Granger, Indiana |
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 CoachE
rrApprentice Cincinnati, ohio -usa |
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 BeltFedBrowning
rrKey Veteran Kansas City |
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| v22chap
rrKey Veteran Granger, Indiana |
I was teaching my 13 yr old son to fly pod and boom heli at the local airport and it started to drizzle . We had drove 45 mins to do that and didn't want to go back home right away so we went inside the small lobby and read magazines until it stopped raining . My son came running over and showed me a 3 X 5" picture with a small caption under it of the new proto type of a tilt rotor ... the XV -15 tilt rotor . We drooled over it and talked some about it and possibilities of a model ,, for me it was just to pass the time and have fun with my son ,, not for my young son . Weeks later he came to me and asked when we were going to start on the tilt rotor build !!!! I told him in all honesty that it couldn't be done and I only had one helicopter to make it out of at that time ,,, and really should not of had that ,, raising a family and all . A week later he came to me showing me drawings in his note book of how he thought we should build it ... even had it worked out to go to a friend and borrow some heli parts from to do it . I in all of my wisdom , said "NO" it just would not work !! That night I couldn't go to sleep. I kept thinking about what I said and that "hey that is what my Dad use to do .. I would tear something apart to make it work like the real thing did and then he would have to put it back together ... and he always would yell at me .. why do you do that !!" I decided then and there that I was not going to do that to my son . So the next morning before he left for school I told him to tear apart my heli as we were going to built a tilt rotor ,,, even though in my mind I " KNEW " it wasn't going to work , but wanted to instill confidence in my son by listening to his ideas . Over the next weeks/ months we built this "thing" that slightly resembled a tilt rotor
It had swizzle stick side fuselage (3/8 " X 1 " sticks , glued together wide at the nose and pulled together at the tail .) the wing was an old foam wing off a crashed super chipmunk ... home made gearboxes on the tips with my GMP cobra head on one side and my friends schluter superior head on the other side . The .60 motor sat in the center of the wing with 1/8" piano wire to the gearboxes ,, just setting out in the open on top of the wing . The control was a mechanical mixer in the nose .. with 2 3/8" wood dowel control rods going at an angle back to both the nacelle gearboxes . I wish I had the 1 picture we took (as I didn't think it would amount to anything ) .. and those 2 (walmart free duplicates) got lost in the divorce that later occurred . With a couple months of work and the knowledge that this was not going to work, my son and I headed to the airport . The thing shook and vibrated ,, the control rods flooped up and down .... BUT it lifted right off the ground and hovered ,,, and hovered good !!!! The only problem was the foam wing had no spar and when it would lift off the nacelles would move up about 2 "before the landing gear would lift off the ground .. so no forward flight with a flare to landing was ever made on this contraption .. but it was worked on that winter and made stronger and better . The next version would not lift off as we had changed to much and had to go back and recreate the 1 st ones gearing and all to get it back in the air again ... so lesson learned .. document what you have done and then only change one thing at a time and see what it does ! We did more work on it over the next yrs ,,, but long story short .. when my son graduated from high school ... what do you think a farmer/contractors son wanted to do ? He wanted to go to college to become an aeronautical engineer !!!! I WONDER where that came from ! I am so happy that I took those days / yrs to work with my son !!! He went on to graduate / serve in the military and then go to work on the B-47 UCAS( unmanned combat aerial system ) that Northrop Grumman is working on . This is a flying wing type plane with a 62 foot wingspan , that flies totally by computer and is capable of carrying around 5000 lbs of ordinance and can land on a pitching aircraft carrier !!! He went on to college and I continued on my own trying this and that ... which is my way of doing things .. I wrote him one yr and said hey ... college man ,,, help . He wrote me a small book of testing things I needed to do to have him help me .... I told him I would just stagger on ,,as that was simpler than doing all the various test he needed performed to help me any more than he did at the start !
All this from a farmer that never had the chance to go to college , my son was the first in our family to go to college !!! I am so proud of him I could bust ! |
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| v22chap
rrKey Veteran Granger, Indiana |
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| whirlyspud
rrKey Veteran USA |
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| v22chap
rrKey Veteran Granger, Indiana |
I fought for a whole day to get the wing attachement to work right .. finally ended up cutting the wing bolt mounts out and replacing them as it just wouldn't fit and leave the wing centered and squared on the fuse !! Don't look to close as I am not taking the time to be detailed in the wood work .. as this fuse is probably short lived anyhow . I just want it up and flyable to prove or disprove the rotormast FC unit on this big of bird .But it will give you other builders an idea of what I did to get the look .It is pretty simply just 4 - 3/4" stringers on 8- 3/16" formers to make a box and 1/16 " balsa around that all sanded to shape .1/8" carbon dowel rod drilled and glued in centers of the 3/4 " tri -stock to reinforce the joint , new to old stock, and a 3/4" square balsa over it to help      |
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| Girard Ibanez
rrVeteran Tucson, Arizona (formally from Guam) |
Team Thunder Tiger since 6/2005 to 12/2014 |
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| v22chap
rrKey Veteran Granger, Indiana |
 Now this is looking more like a shop 
 Might have been easier to just start all over ,, flush and square !
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| darrelluh1b
rrApprentice Dalton Ga |
Darrell |
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| v22chap
rrKey Veteran Granger, Indiana |
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| v22chap
rrKey Veteran Granger, Indiana |
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| v22chap
rrKey Veteran Granger, Indiana |
Either I have forgot how to apply it because it has been so long since I've done any or I just don't have the grip to tug it tight around corners any more 
But towards the end of this mess I realized that the 17 yr old roll of monokote I was using ,, has been stored that long in a hot attic !!So that is lending to the problem as it already has wrinkles in it (already pre shrunk ) and the last picture of this is towards the end of the roll and looks better than the first of the roll . I noticed this when I tried to re shrink the rest of the monokote on the bird .. It won't shrink up any more . Don't use really old wrinkled monokote ,, atleast on compound curves .. laying it on the flat worked pretty much . So it all looks bad
But,,, it will be good enough for the electric proto and for as long as it probably will last   |
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| BeltFedBrowning
rrKey Veteran Kansas City |
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| v22chap
rrKey Veteran Granger, Indiana |
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 Heli143
rrElite Veteran Phenix City, Alabama 💎Sustaining Member |
Following along with your build with a lot of admiration for your skills. |
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| v22chap
rrKey Veteran Granger, Indiana |
This is really just grab parts and start somewhere and may have to be remade , several times before finding the right match ! I did do a little online calc for motor size and gearing and such .. but the actual side frame design and such is some where in my head :wacko: I have two Guai 450's to be donor mechanics and am just sandwiching the gear box area in-between carbon side frames ... I needed two stage gear setup as the nacelles are really narrow when in side the nacelle trim for scale . So I start out making the side frames from cardboard as it is plentiful and easy to cut / throw away and re cut !!! So this may take a while as there are a lot of home made carbon fiber parts and aluminum bellcranks and home made pushrods !!! Yes I have made pushrods for yrs now . The old thick black coat hangers and a die do for quick and exact size without trying to find the right ones online in a kit listing of parts !!Donor mechanics before my hack saw
 Donor gearbox and card board pattern
 first card board pattern and a couple more to follow .. as I decided to move the motor from the up position to a down and tucked in position to make the nacelle rotate more free with out so much weight on top and sticking out front .
 motor to the bottom ---------- Notice now that I have the major layout worked out with the card board ,, I have moved to scrap plywood which keeps the measurement holes and such lined up better and can be bolted together to see how it all lines up and I haven't wasted any carbon fiber ,,,, yet
 This is where it usually mounts per kit .
 finished / bolted together plywood pattern .This might actually work .  |
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| v22chap
rrKey Veteran Granger, Indiana |
 And a couple of the hand made bell cranks needed for the cyclic and bell cranks mounted |
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