LA Heli MaxiR Std. Full Build Thread...
 

Build Log - LA Heli MaxiR Standard Kit Full Build Thread... Lots Of Photos and Full Text
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Here I go...

My Standard MaxiR kit arrived today from Pete at ElektroRc.com. Great place to do business with, Pete's a great guy and cares about his customers. Here's a pic of the kit box along with the upgrades I plan on installing. The upgrades include:

Aluminum Swashplate (silver)
Aluminum Rotor Head (silver)
Auto-Rotation Gear
Carbon Fiber 3D Paddles/Short Flybar
Carbon Fiber Main Blades
Carbon Fiber Tail Blades

http://www.whirlybirdz.com/images/ma...t_contents.jpg

Additionally I'll be installing one extra bearing in the tail boom, this requires the purchase of part # Y0424. These are small plastic "cups" which adapt the bearings OD to the ID of the tail boom.

Here's a pic of the kit box and upgrade parts:

DISCLAIMER: This thread documents how I build MY heli. If you find the information here useful that's great. But I assume no liability for anyone else or their heli or any other aspect of their lives that chooses to follow this thread as an instruction manual. Build and fly your heli's at your own risk. And always fly safely.

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Frame assembly Part 1...
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Part one consists mainly of installing the two main shaft bearings in the Upper and Lower Main Shaft Housings, and assembly of the Battery Holder Plate and the small white Battery Plate Clips which secure the Battery Holder Plate to the Undercarriage Rods on the front of the frame. The other thing you do in step one is install the Swashplate Lead(anti-rotation device).

For each step that requires installing bearings, I set the bearings for that step on a folded piece of paper towel and put one drop of tri-flow oil on each bearing. At the same time I check for bad bearings, if a bearing is even slightly gritty feeling, REPLACE IT! A bad bearing will give you nothing but problems.

NOTE: Since I'm installing the metal swashplate upgrade, the Swashplate Lead Pin is not installed in this step of my build, the metal swashplate uses a different anti-rotation device: Cyclic Plate Guide which is secured with a screw.

Here's a pic of the parts needed in step one of the build:

http://www.whirlybirdz.com/images/maxir_1/step1_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Pics of the Fuselage...
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Ask and you shall receive...

http://www.whirlybirdz.com/images/ma...fuse_1_800.jpg

http://www.whirlybirdz.com/images/ma...fuse_2_800.jpg

http://www.whirlybirdz.com/images/ma...fuse_3_800.jpg

http://www.whirlybirdz.com/images/ma...fuse_4_800.jpg

http://www.whirlybirdz.com/images/ma...fuse_5_800.jpg

http://www.whirlybirdz.com/images/ma...fuse_6_800.jpg

There ya go...

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Step one completed...
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This is what you should have after completing step one...

http://www.whirlybirdz.com/images/ma...e_done_800.jpg

Coming up...the start of the frame assembly...

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

The easiest way to install the small white Battery Plate Clips is to grasp them with a GOOD pair of needle nose pliers, squeeze the open end together and push them into the openings in the Battery Holder Plate....open end first

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Frame Assembly Step two......starting on the actual frame...
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Here's a pic of the parts you'll be using in step two. Mostly you'll be working with the right side frame plate, installing the Undercarriage Triangles, Servo Holders and Upper and Lower Main Shaft Housings. Leave the main shaft housing screws loose until you have the main shaft in place and aligned properly. You also need to install the two Electronics Plates...

http://www.whirlybirdz.com/images/ma...step_2_800.jpg

In the next post I'll show the completed step two.

RE: LA Heli MaxiR Std. Full Build Thread...
 

Frame Assembly Steps One & two completed...
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Combining the sub-assemblies from step one and the parts for step two you should end up with this........ As I stated before; leave the Upper and Lower Main Shaft Housing screws loose for now. I'll tighten them up after the main shaft is installed and aligned. Here's a couple pics after step two of the frame assembly is completed...

http://www.whirlybirdz.com/images/ma...t_side_800.jpg

http://www.whirlybirdz.com/images/ma...t_side_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

On to the Rotor Head build........

NOTE: I'm installing an upgrade metal Rotor Head, but everything looks to be the same between the aluminum Rotor Head and the stock plastic Rotor Head . Another thing to make note of is the swashplate: the stock Swashplate is NOT assembled. I'm also installing an upgraded aluminum swashplate, But I'll photograph and document the build of the stock swashplate assembly.

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Rotor Head Part One...
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Here's a pic of the parts needed for the Rotor Head Assembly Part One...

I'm installing an upgrade aluminum Rotor Head, shown next to the stock black plastic Rotor Head. They are virtually identical. Note the small protrusions on the two small DOG POINT set screws. The Paddle Bearing Housing bearings sit on these small portions of the DOG POINT set screws. More about this later...

http://www.whirlybirdz.com/images/ma...part_1_800.JPG

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

A small note: on the landing gear skids there are small "nubbins" protruding from the top of the skids, on my first MaxiR I mistook these for flash and removed them....NOT THIS TIME. Leave the small plastic protrusions alone, the landing gear struts sit between them.

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Ok....now some REAL detail.......

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Here's where you need to pay attention to what you're doing. The Paddle Bearing Housing MUST BE PERFECTLY CENTERED in the head block. It takes a little patience and thinking to do it without making a mess with an aluminum head block BECAUSE you must use threadlocker on the ally head. SO here's how I do it.....after the bearings are in the PBH, DO NOT USE THREADLOCKER YET!!!
Start one of the small DOG POINT Set Screws into the head block, thread it into the head block enough to see the tip of the Dog Point Set Screw protruding into the center opening. Slip the Paddle Bearing Housing into the head block.....MAKE SURE it's centered on the tip of the DOG POINT set screw. Now thread the other Dog Point Set Screw in...as soon as it touches(centered in the bearing inner race) STOP!

Carefully observe the centering of the Paddle Bearing Housing in the space of the head block....if it needs to move one way or the other, loosen the set screw a 1/4 turn at a time and tighten the other. Keep at this until it is perfectly centered and has absolutely free movement and no side to side slop.

NOW! Take out one set screw... ONLY ONE !!!... Apply the smallest bit of threadlocker on the threads that are towards the OUTSIDE. Apply only enough to get two of those tiny threads wet on the screw. Reinsert the screw, do not "tighten" it, instead snug it up until you feel it bottom out and your sure it's centered in the bearing. STOP THERE!

Now take out the other DOG POINT set screw apply threadlocker(just a weeeeee bit)and repeat the procedure of "snugging it up" Confirm centering of the Paddle Bearing Housing and ABSOLUTELY FREE movement and no slop. If all is good leave it alone. Your done with this part.

Here's a pic of the partially completed head assembly and a pic of the DOG POINT set screws.... I'll do my assembly of the Paddle Bearing Housing and take a pic of the centering, stay tuned...

http://www.whirlybirdz.com/images/ma...head_1_800.JPG

http://www.whirlybirdz.com/images/ma...arn_screws.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Paddle Bearing Housing...centered in head block...
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Here's pic of the Paddle Bearing Housing after mounting in the head block, It's a little hard to see but you can just see "daylight" around the entire perimeter of the Paddle Bearing Housing...

http://www.whirlybirdz.com/images/ma...H_centered.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Completion of Rotor Head Step One...
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The completion of Rotor Head Step One is pretty straight-forward... install the O-Ring Supports, O-Rings and Blade Grip Bearings on the Cross Head Shaft, tighten the two nylock nuts until the blade grip bearings are firmly snugged up against the O-Ring Supports, NOT TOO TIGHT!.....this is your HEAD DAMPENING!...... Here's a pic of the completed Rotor Head Part One...

http://www.whirlybirdz.com/images/ma...part_1_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

A little kit building tip...
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When working on a kit, it's a great idea to have some small, easy to use containers for keeping your small parts organized during the build.....I found these at a surplus store, they came in a pack of ten or so and are perfect for hobby use....if you can find something like these grab em, they are ususally inexpensive to purchase and very helpful during a build......these actually have cardstock inserts in the lids so you can label them easily with a pen or marker...

http://www.whirlybirdz.com/images/ma...ts_holders.JPG

Ken

BTW: I told ya I'd get the correct nomenclature for those darn screws! And I did! There's another type that looks almost identical and they're called Soft Point Set Screws...The ones in the head block are DOG POINT set Screws..... just thought I'd get the facts straight for you all.

RE: LA Heli MaxiR Std. Full Build Thread...
 

Blade Holders...
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Step Two of the Rotor Head assembly is basically installing the upper and lower blade holders using 4 Self tapping screws. Here's a pic of the stock Upper and Lower Blade Holders also a set of upgrade one piece Aluminum Blade Holders (INCREDIBLE MACHINING ON THESE! (believe me I know!))...

http://www.whirlybirdz.com/images/ma...de_holders.JPG

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Rotor Head Part Two completed...
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Here are some pics of the Rotor Head during/after the assembly is completed following Part Two in the instruction manual...

http://www.whirlybirdz.com/images/ma...rt_2_1_800.jpg

http://www.whirlybirdz.com/images/ma...rt_2_2_800.jpg

http://www.whirlybirdz.com/images/ma...rt_2_3_800.jpg

http://www.whirlybirdz.com/images/ma...rt_2_4_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Rotor Head Part Three...
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Here's a pic of the parts needed for assembly during Part Three of the Rotor Head build...

http://www.whirlybirdz.com/images/ma...rt_3_1_800.jpg

I'll post some pics of the assembly steps as I go along...

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Here's a pic of the partial assembly during Part Three of the Rotor Head build....

http://www.whirlybirdz.com/images/ma...t_3a_1_800.jpg

The completed Part Three of the Rotor Head build in a few minutes.....

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Completed Rotor Head Part 3

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Here's a pic of the completed assembly of Rotor Head Part Three in the manual. This is a time during the assembly where you want to look for any "flash" around the openings in the Collective Mixer and on the small parts Y0426 (white plastic bushings, 4x2mm) Use an emery board, a file, exacto knife or fine sandpaper to remove any flash on these parts, they must move absolutely freely. Use a very small bit of threadlocker on the SHC screws which secure the Collective Mixer to the Collective Mixer Housing. DO NOT get any threadlocker on the small bushings or plastic parts, it will destroy certain types of plastic, best not to take chances.

The two SHC screws which secure the Collective Mixer to the Collective Mixer Housing also secure the flybar wire in place, after the flybar is centered would be the correct time to apply threadlocker to those screws and tighten them completely..

Assembly is very straightforward, but pay attention to the "boss" on the one side of the Blade Holder Lever Y0312.

Here's the pics:

http://www.whirlybirdz.com/images/ma...t_3b_1_800.jpg

http://www.whirlybirdz.com/images/ma...t_3b_2_800.jpg

http://www.whirlybirdz.com/images/ma...t_3b_3_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Rotor Head Part Four...
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Here's a pic of the kit parts needed for Part Four Rotor Head assembly......again look for flash on the Blade Holder Lever and Pushrod Long and the Ball Joint w/Ball Junction. These parts must move freely with no slop.

http://www.whirlybirdz.com/images/ma...rt_4_1_800.jpg

Next a pic of the components assembled from Part Four Rotor Head...

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Rotor Head Part Four Complete...
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I know these last few steps seemed kinda easy...well, they are. The next few steps are where all of these sub-assemblies come together and become the MaxiR Rotor Head. The manual has almost no text for these steps, so I'll document each Part of the assembly with text and photos...

Here's a pic of Rotor Head Part Four Completed...

http://www.whirlybirdz.com/images/ma...Part_4_800.jpg

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

I don't know about you, but I need some head...
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Here's a pic of all of the sub-assemblies and parts needed to complete the MaxiR Rotor Head...

http://www.whirlybirdz.com/images/maxir_1/Need_head.JPG

I'll show the assembly as I do each main step, the manual breaks it down into two parts.....I'll show it as a few more so you can see what's going on...

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Completing the MaxiR Rotor Head...
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Insert the flybar into the ball end of the Collective Mixer Housing(Y0310), continue to insert it through the "slit" in the Pushrod Long(Y0308). Next insert that end of the flybar into the opening in the end of the Paddle Bearing Housing(Y0307). You should end up with something that looks like this...

http://www.whirlybirdz.com/images/ma...complete_1.JPG

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

More Maxir Rotor Head assembly...
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Using one of the 1.6X6mm screws insert it through one of the small white plastic bushings 4X1.6 and fasten the Blade Holder Lever(Y0312) to the blade grip. Be sure the small taper on the bushing is towards the Blade Grip... Heres a pic of what you should have now...

http://www.whirlybirdz.com/images/ma...complete_4.JPG

Ken

RE: LA Heli MaxiR Std. Full Build Thread...
 

Other side of the Rotor Head...
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Assembling the other side of the Rotor Head is somewhat similar with the exception that were installing from the other direction onto the Flybar... Also there's no Collective Mixer on the other side. That's the reason for the Brass Counterweight W/Ball(Y0309). After slipping the flybar through the "slit" in the other Pushrod Long(Y0308) insert the flybar through the Counterweight w/Ball from the flat side... Attach the Blade Holder Lever to the other Blade grip same as the first one using the 1.6X6mm SHC screw and the small white plastic Bushing 4X1.6... Last thing is to install the two Double Ball Joint Pushrods onto the Collective Mixer. That completes the main assembly of the Rotor Head, we still need to align the Flybar and tighten the set screws on the Counterweight w/Ball and Collective Mixer Housing, but the assembly is complete... Here's some pics...

http://www.whirlybirdz.com/images/ma...complete_4.JPG

http://www.whirlybirdz.com/images/ma...complete_5.JPG

http://www.whirlybirdz.com/images/ma...complete_9.JPG

http://www.whirlybirdz.com/images/ma...omplete_10.JPG

More fun to come... Ken