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The Model
Part 1 - Chassis
Part 2 - Tail
Part 3 - U/Carriage
Part 4 - Servos
Part 5 - Electrics
Part 6 - Flight Trials
Part 7 - Assembly
Pictures
Analysis
 
        

 

Scratch Built Collective Pitch - Hummingbird / Hornet Hybrid

Part 7 - Assembly / Finishing

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CHASSIS

After initial flight checks I stripped down the entire helicopter to its base components.

I started the finishing process by polishing all the aluminium parts to a mirror finish with a drill mounted buffing pad and Solvol chrome polish. Where I couldnt polish easily inside the 'C' section I sprayed with metallic blue after priming.

After assembling the main chassis and aligning the main shaft I sprayed all the exposed alluminium with one coat of pearl laquer then several clear laquer to stop any oxidisation. the pictures here dont really show the results which I am pleased with.

The tail section was then treated similarily. The tail motor mount was fitted after threading through 3 wires to power the brushless tail motor, the 8mm DIA tube has plenty of space for this.

 
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CARBON PARTS

Although the carbon fibre parts look really nice in their bare finish I wanted something different.

I decided that I would try making some full cover decals out of inkjet acetate, these would be printed in reverse, stuck on to the carbon fibre with the gloss side out and finished with laquer.

In this way the carbon weave would still show through plus all the cut out portions of the carbon frames would catch light through the acetate.

I started by exporting the outline of the

 

sideframes and tail surfaces from Autocad which I made 1mm smaller overall, then used a really powerful drawing package called CorelDraw to open the .dwg file. I then converted the line drawings to objects and then experimented with different fill patterns and textures of which there are many in CorelDraw.

Having decided on a blue texture fill I then made versions for left and right faces plus exposed inner faces.

The carbon parts were cleaned and and filing completed. After printing off the decals I applied using faithful spraymount spraying both sides of the carbon parts and applying the decals to them to prevent any overspray appearing on the cut out portions.

Each part was given one coat of pearl lacquer to catch the light then several coats of clear laquer, I am incredibly pleased with the results, which look different and stunning.

If you have CorelDraw and would like to download the file right click the following link and choose 'Save Target As...'

Hybrid CCPM Decals.cdr

 
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ASSEMBLY

The sideframes were then fitted in place with hex head M3 bolts.

This picture shows light shining through the cut out portions highlighting the decals.

 
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The remaining carbon parts, horizontal and vertical tail fins and tail support were then fitted in place.

The vertical tail fin acts as a tail rotor guard.

 
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I then fitted the tail motor mount, motor and carbon tail blade.

 
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The servos were then mounted in place on the carbon servoplate and locked in position with the locking collar and CA

 
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The head assembly was then made up and fitted. I am using all aluminium components for the nicest flying helicopter possible, they look fantastic too!

It is worth spending some time ensuring everything is of equal length and moves easily on respective ballends

The Flybar was then fitted as shown below.

Next came all the electrical components, I trimmed down all cable lengths and used tiewraps to secure keeping everythign as neat as possible.

I also fitted the antenna at this stage.

 
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The SAB main blades were then fitted, these are longer than standard but narrower in chord, in my view they are very good quality, work well and look fantastic.

Finally I mounted a short bar through the top rail of the chassis to hold the GRP based canopy.

Pictures of the finished helicopter are on the 'pictures' page.

 
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