RE: Ultimate #36 Mod Thread (& Shogun Parts)

RE: Ultimate #36 Mod Thread (& Shogun Parts)
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RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/19/2006 4:17:55 AM

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From: Selangor, MALAYSIA
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And here's the final produc:

Here's the channel opening directing air onto the motor. Incidently the motor case rotation is in the opposite direction to the air flow, which I believe, improves heat exchange:

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/19/2006 4:19:03 AM

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Here's how it looks like installed:

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/19/2006 4:20:50 AM

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The efficiency of air being pushed by the main gear fins is improved by the closeness (1 mm) of the air channel to the fins:

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/19/2006 4:23:53 AM

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Fully installed:

Morning flights (cool in the tropics) of 8 minutes now show the motor to be only luke warm. I now confidently fly 8 minute flights back to back, and still have the heli down with only a warm motor. Fantastic!!

Anyway, thats it for today. Happy flying and cheers!

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/19/2006 5:01:24 AM

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From: MelbourneVic, AUSTRALIA
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Creative and Inspired as usual Mr Bear..

What sort of modelling putty do you use to create your duct ? I've been tinkering about with making shapes with some tamiya 2-part part putty, thick CA on masking tape, accelerator spray, dremels, and so on.

I read a while back about some plastic you can get that can be repeatedly softened in a glass of near-boiling water then molded into shape while it cools and sets hard. It always interesting to hear how other people fabricate their own custom parts.

You know, that duct might be a popular item for the T-Rex upgrade world.. perhaps you should get in touch with Align or MicroHeli or any of the aftermarket parts guys. Bulk manufacturing of plastic parts is not usually a good area for small operators, but they might express some appreication for your design ideas in parts or a frame or something..

I saw the movie "The Worlds Fastest Indian" the other day. You remind me of Bert Munro with your customised beast.

_____________________________

Rotorcraft Pilots dont "Fly" - They *beat* the air into Submission !

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 2:17:42 AM

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Spockie-Tech, I use 'Play Dough' to make the initial shape (s).

. Its kiddies stuff, cheap, easily available and does not stick to epoxy. I think that Tamiya stuff of yours would be much better.

To build the structure, I apply the epoxy first - make a thin layer. Then I apply fibre glass cloth over this layer. The fibre glass will absorb the epoxy. Add additional epoxy to add more fibre glass layers.
Wait until the epoxy dries, then remove the Play Dough. WALAAH! You have a structure!
Using this simple technique, you can have the wall as thin as you like.

To smoothen up the surface for painting, I sometimes add CA and powder. Grind to shape, sand paper smooth, then paint.

Good luck!

(in reply to Spockie-Tech)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 2:49:04 AM

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I usually don't do a mid week mod (as I like to fly before going to work) - but this week is an exception. A big one!
The two-one way bearing idea to 'float' the main shaft worked beyond expectiong. Turning off the motor at 100 feet up resulted in a slow decent with rotor spinning not ONLY due to the inertia but also by the passing air movement. It is so slow, it looks like a powered decent!

To improve on this further, I just HAD to improve on this 'floating' mechanism.

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 2:53:38 AM

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To recap - my first prototype used used two bearings to keep both the main gear and the tail drive pully 'floated' around the one way sleeve:

Though this system worked, the second one way bearing - caused a lot of rotative friction around the one way sleeve due to the large surface contact of the bearing rods. This would sap a lot of energy from this rotating system:

Somehow, I had to get rid of this second bearing.

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 2:57:49 AM

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So I went back to the drive pully from xmseller. This is what it looked like months back when it was new:

This drive pully was designed to be attached to the one way sleeve via a grub nut.

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RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:01:01 AM

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This is what it looks like now - six months on and tons of mods under its belt:

I took it my favorate RE-engineering firm and asked them to bore a hole through the middle, of exactly the same size as the one way bearing:

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RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:04:18 AM

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I went back to my microheli Trex main gear for attachment with this pully via the one way bearing AND 4 bolts and nuts.

I decided to abandon the Blue Align main gear as I couldn't put the support bolts exactly opposite to each other (see earlier posts). With the microheli main gear, this could be done easily.

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:06:21 AM

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I remove the microheli center hub for ease of putting metal based epoxy between the two stuctures:

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RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:08:58 AM

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Top side, at the tail drive pully opening, there is just enough space to put THE ORIGINAL WALKERA #36 MAIN BEARING. So here it is (arrow)!!:

The answer to the two - one-way-bearing problem - Add a conventional bearing! So easy!

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:10:55 AM

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Here's a close up:

The conventional bearing's function is to keep the drive pully centered and to support this drive system - minus the large friction area of the one-way-bearing.

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RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/21/2006 3:14:25 AM

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Problem one sloved!

The next problem was to ensure the two never separates during flight (catasthrophic!) - I use four bolts, and metal epoxy to join the two. The two long bolts will be secured further with nuts.

Thats where I stopped last night. My heli is again in pieces but maaaan am I excited!!

Will report when I test out the new system. Till then, happy flying and good luck!

(in reply to borneobear)

RE: Ultimate #36 Mod Thread (& Shogun Parts) - 9/22/2006 3:42:04 AM

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Well okay. I got the Microheli main gear, hub and tail drive pully back together and here's what it looks like:
Bottom view:

Top view:

The funny thing about fitting the one way bearing to these one main gears (including the Align blue / white gears) is that you have to push or knock them in at precisely 90 degrees angle. Failure to do so will result in the gear wobbling. I would love to have a screw press machine, but which hobbyist on earth does? (Sorry for ranting). Anyway, after the second try I got it in almost pefectly (minimal wobble).

(in reply to borneobear)