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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
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Scratch Built Collective Pitch Hornet Hybrid V2

Part 1 - Chassis

The main chassis consist of two plates of 1.5mm Carbon Fibre sheet, between them are two spacers made from 12.5mm thick Delrin. Delrin is a plastic that is both light, strong and easily worked with normal hand tools. The plates are joined together with M3 hex head bolts and nyloc nuts.

The central pillar supporting the main mast is made from 8mm dia Aluminium tube with collars of 10mm and internal spacer of 6mm tube.

There are an additional two components made of carbon fibre for the location of servos and positioning some of the electrical components.

 
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Chassis

As before I printed out the templates at 1:1 scale from AutoCAD nad used spraymount to stick them to carbon sheet.

After cutting with a Dremel and filing to shape any templates that where to have common holes drilled in them where joined together either with tape or by bolting before drilling out.

 
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The front and rear spacers where cut out of Delrin sheet and filed to shape. An 8mm hole is drilled through the rear 'T' shaped section for moutning the tailboom. In the top of this piece I drilled two holes and tapped them to accept two M3 grub screws that lock the tailboom in place.

Once completed all the chassis components where cleaned ready for assembly

 
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The main mast is produced from an outer tube of 8mm Alloy. Over this is and from the top is slid a 10mm length of 10mm dia alloy tube and from the bottom a 3mm length.

These components are all glued into place using JB Weld checking for square as work proceeds.

 
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Above the 10mm long tube fits the Servoplate itself which again is locked by a 5mm length of 10mm dia tube JB Welded in place.

The entire construction is very strong and will not break in a moderate to heavy crash

I am only using two bearings for this version which are seprated within the main mast by a length of 6mm dia tube

 
 
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The servoplate is fixed in position via 3 10mm long nylon standoffs as can be seen here

 
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The mainshaft can now be fitted with locking collars at top and bottom.

After experimentation I have found the best distance between the top face of the Servoplate and the Mainmast Head Pin is 50mm

 
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I stuck a template to the top of the delrin sheet to fabricate the front and rear spacer blocks.

These where simply cut out with a hacksaw, drilled then filed to shape

 
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The entire chassis is now bolted together and everything checked for true and smooth operation