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Bergen INTREPID GAS Owner'S Manual Download Page 16

 

1 

 

M1000 

ALUMINUM TAIL ROTOR GEAR BOX ASSEMBLY 

 

1 

M1000A 

GEAR BOX ONLY 

 

1 

5094 

3X3M SET SCREW 

 

2 

5095 

3X4M SET SCREW 

 

1 

M1000B 

PITCH ARM BRACKET 

 

1 

M1000F 

REPLACEMENT GEAR SET W/OUTPUT SHAFT

 

 

 

 

TWIN 

1000D 

OUTPUT SHAFT 

 

1 

 

BEVEL GEAR 

 

1 

 

BEAVEL GEAR W/SHAFT 

 

1 

1000E 

10M PIN 

 

1 

5095 

3X4M SETSCREW 

 

1 

M1000C 

ALUMINUM SPACER 

 

1 

3071 

10X15X4 FLANGE BEARING 

 

3 

3055 

5X13X4 BEARING 

 

1 

1210 

12M PIN 

 

1 

1000I 

INPUT SHAFT FOR GEAR BOX 

 

1 

M1000J 

BRASS SPACER TUBE 

 

1 

5025 

3X5 PAN HEAD SCREW 

 

2 

5001 

3X4 SHCS 

 

2 

5090 

3X8 FLAT HEAD CAP SCREWS 

 

 

 

ASSEMBLY 5 

2 PAIR 

 

1665 

TAILBOOM CLAMPS  

1 

 

1667 

HORIZONTAL FIN CLAMP 

 

 

 

MISC BAG 

2 

 

109DA 

COLLARS FOR TORQUE TUBE DRIVE 

1 

* 

5050 

3X35 SHCS 

4 

* 

 

3X30 SHCS 

1 

 

9015 

DOGBONE 

1 

 

9020 

DOGBONE PIN 

2 

* 

5020 

3X12 SHCS 

4 

* 

5110 

3M WASHERS 

7 

* 

5105 

3M LOCKNUTS 

2 

* 

5010 

3X8 SHCS  

6 

* 

5094 

3X3 SET SCREWS  

Summary of Contents for INTREPID GAS

Page 1: ...INTREPID GAS and GAS EB INTREPID GAS and GAS EB INTREPID GAS and GAS EB INTREPID GAS and GAS EB...

Page 2: ...Owners Manual Owners Manual Owners Manual Owners Manual Assembly Assembly Assembly Assembly Instructions Instructions Instructions Instructions...

Page 3: ...INTREPID GAS Table Of Contents...

Page 4: ...rplanes Helicopters by their nature are not positively stable meaning that even if properly assembled and adjusted helicopters will not recover from an unwanted flight attitude nor will they hold any...

Page 5: ...er Staff Chris Bergen Chief Executive Officer Larry Bergen Chief Design Engineer and General Manager Mary Ann Pratt Marketing Sales and Service Terri Demeyer Office Management Mike Bergen Programmer E...

Page 6: ...uccessfully build and fly their INTREPID the process can be made significantly easier with the help of an experienced modeler and instructor pilot We recommend that all beginners join the Academy of M...

Page 7: ...this period We make no warranty express or implied This warranty does not apply to parts damaged by improper assembly modification abnormal service or handling or crashes 2 To take advantage of this w...

Page 8: ...S OR ANY DAMAGES DUE TO THE USE OR INABILITY TO USE THIS PRODUCT Bergen R C shall not be liable or in any way responsible for any damages related to modifications repairs attempted repairs or crashes...

Page 9: ...at 269 445 2060 e mail at bergenrc frontier com contact us on bergenrc com or you can usually find me and many Bergen owners on http helifreak com For updates hints tips and new things we re working...

Page 10: ...OUNT SPACERS 2 1933 or 1934 STANDOFF 24M FOR LEXAN OR 18M STANDOFF FOR FIBERGLASS 2 5102 3X12 SS 2 5010 3X8 SHCS BAG 3 1 1415 FAN ASSEMBLY 1 1420 GAS FAN 1 1425 GAS FAN HUB 3 5010 3X8 SHCS 1 1455 FAN...

Page 11: ...4 3034 6X12X4F BEARING 2 1620 COLLECTIVE AXLE 3 5055 3X40 SHCS 1 1250 MAIN SHAFT BEARING BLOCK ASSEMBLY 1 3040 10X19X7 BEARINGS 1 1255 BEARING BLOCK ONLY 7 5050 3X35M SHCS 2 5001 3X4M SHCS 10 5105 3M...

Page 12: ...0C PINION SPACER BRASS 1 1745 PINION GEAR 1 5094 3X3 SS BAG 6 1 1233 MAIN SHAFT ASSEMBLY 1 1235 MAIN SHAFT 1 1241 MAIN SHAFT COLLAR 1 5160 4 40X1 2 AMERICAN BOLT 2 1245 SPLIT MAIN SHAFT COLLAR ASSEMBL...

Page 13: ...BRASS WASHER 2 1205 RADIUS LINK 2 1000E RADIUS LINK PIN 6 5190 SHORT BALL 1 1215 SWASH PLATE ASSEMBLY 4 5094 3X3 SS 4 5195 MEDIUM BALL BAG8 2 1616 COLLECTIVE ARM 1 1625 COLLECTIVE BELLCRANK TRIPLE 1 1...

Page 14: ...NG 2 5136 3X12M W 6M SHOULDER SHCS 2 5115 3M NUT 1 1106 HEAD BLOCK 2 1111 BLADE GRIP ASSEMBLY 2 1116 BLADE GRIP W O BEARING 4 3005 8X16X5 BEARING 2 3006 8X16X5 THRUST BEARING 2 1126 BLADE GRIP PITCH A...

Page 15: ...BELLCRANK ASSEMBLY 1 240A DELRIN INSERT 1 240D ALUMINUM BELLCRANK ONLY 1 240C ALUMINUM SPACER 2 3086 3X7X3 FLANGE BEARING 1 5140 3X16 W 6M SHOULDER SHCS 2 5155 3M BRASS WASHER 1 5195 MEDIUM BALL 1 51...

Page 16: ...C ALUMINUM SPACER 1 3071 10X15X4 FLANGE BEARING 3 3055 5X13X4 BEARING 1 1210 12M PIN 1 1000I INPUT SHAFT FOR GEAR BOX 1 M1000J BRASS SPACER TUBE 1 5025 3X5 PAN HEAD SCREW 2 5001 3X4 SHCS 2 5090 3X8 FL...

Page 17: ...2 1956 BALL LINK 2 5 2 5105 3M LOCKNUT 2 5035 3X20M SHCS 1 1709 TAILBOOM SUPPORT SET 2 1710 TAIL BOOM SUPPORT STRUTS 4 1715 TAILBOOM SUPPORT STRUT ENDS 1 M1830 HORIZONTALFIN 1 M1835 VERTICAL FIN BAG 1...

Page 18: ...4X12M SHCS 5065 9 4X16M SHCS 5069 2 5X65M SHCS 5072 2 5X16M SHCS 5085 4 5X12M SHCS 5086 1 6X25M SHCS 5090 11 3X8M FHCS 5091 3 5X12 FHSCS 5093 2 3X16 FHCS 5094 11 3X3 SS 5095 9 3X4M SET SCREWS 5102 2...

Page 19: ...T 4 5030 3X16 SHCS 6 5105 3M LOCK NUTS 2 5206 3X8 SELF TAP 2 3X16 FHCS BAG 2 1 1506 LOWER FRAME RIGHT 1 1507 LOWER FRAME LEFT 2 1560 SKID BAR 10 5090 3X8 FHCS 1 1517 BATTERY TRAY EXTENDED 2 1530 BATTE...

Page 20: ...90 SHORT BALL 4 5141 3X18 SHCS 4 5105 3M LOCKNUTS 8 231B SPECIAL WASHERS BAG 4 1 1875 FUEL TANK ASSEMBLY 1 1880 FUEL TANK 1 1850 CLUNK 2 1855 SINGLE END FITTING 1 1860 DOUBLE END FITTING 3 1865 FUEL T...

Page 21: ...T 1 1210 COUPLER PIN 1 5095 3X4 SET SCREWS 1 270 FRONT TRANSMISSION SUPPORT ASSEMBLY 1 270A BEARING BLOCK ASSEMBLY 1 3040 10X19X7 BEARING 1 270D BEARING BLOCK ONLY 1 270E BEARING BLOCK SUPPORT CRADLE...

Page 22: ...094 3X3 SS 2 1290 DELRIN BUSHING Set 2 1295 STEEL INSERT 2 1300 DELRIN BUSHINGS 2 5065 4X16 SHCS 4 5308 3X8 LOW HEAD CAP SCREWS 1 1270 MAIN GEAR BAG 7 1 1185 WASHOUT HUB ASSEMBLY 2 1201 WASHOUT MIXING...

Page 23: ...S 2 3020 4X10X4 BEARING 2 1165 4M WASHER SPECIAL 4 5095 3X4 SET SCREW 2 1175 FLYBAR CONTROL ARM 2 1183 FLYBAR PADDLE 6 5190 SHORT BALL 6 5155 3M BRASS WASHER 2 3015 3X10X4 BEARING 2 5205 PAN HEAD SCRE...

Page 24: ...ROTOR MAIN HUB 6M 2 5110 3M WASHER 2 5005 3X6 SHCS 2 5146 3X19 W 11 SHOULDER SHCS 2 5112 10M OD SPACERS 4 231B BLADE GRIP SPACERS 2 5105 3M LOCK NUT 1 5094 3X4 SET SCREW ASSEMBLY 2 1 240 PITCH BELLCR...

Page 25: ...4 3X3 SET SCREW 2 5095 3X4 SET SCREW 1 TWIN 1000B PITCH ARM BRACKET 1 TWIN 1000F REPLACEMENT GEAR SET W OUTPUT SHAFT TWIN 1000D OUTPUT SHAFT 1 TIWN 1000E 10M PIN 1 5095 3X4 SETSCREW 1 TWIN 1000C ALUMI...

Page 26: ...R TWIN BEARING 2 109E O RINGS 4 1945 CANOPY GROMMETS 4 1946 THUMB SCREWS 1 6015 TAIL ROTOR BLADES BAG 10B 1 1170 FLYBAR 1 TWIN 110 TAILBOOM 37 2 2117 ARROW DRIVE SHAFT 2 1879 TIE WRAPS 1 1682 PUSH ROD...

Page 27: ...NOPY 1 242 SAMPLE LOCKTITE 1 2049 ZENOAH G26H ENGINE HARDWARE 5102 2 3X12 SS 5130 1 LOCK WASHER 5120 16 2M NUT 5207 8 2X10 PHSMS 5155 10 3M BRASS WASHER 5110 25 3M WASHERS 5105 40 3M LOCK NUT 5115 2 3...

Page 28: ...WASHER SPECIAL 5060 4 4X12 SHCS 5065 9 4X16 SHCS 5151 2 4X25 SHCS SPECIAL W 18M SHOULDER 5111 2 5X10X2 SPACER WASHER 5091 3 5X12 FHSCS 5085 4 5X12 SHCS 5072 2 5X16 SHCS 5137 8 3 16 BALL W 2M HOLE 506...

Page 29: ...Your Intrepid Gas kit starts off something like this And ends up something like this...

Page 30: ...Lets get started Assemble the landing gear which will require some heat to get the plastic struts onto the aluminum skids Actually it may take a LOT of heat One suggestion is to boil the struts to he...

Page 31: ...your lower frames battery tray spacers and canopy mounts Notice the lower frames have countersunk holes where they attach to the skid bars Use 3X8 FHCS and attach the lower frames It may be necessary...

Page 32: ...Socket Head Cap Screws and 4 ea 3m locknuts secure the landing gear to the skid bars including tightening up the 2 ea 3X16 FHCS and nuts Install an Engine Mounting Spacer with 2 ea 3X8 SHCS to the IN...

Page 33: ...room for weight needed to offset the long tail boom The installation is the same using 6 ea 3X8 FHCS attaching the battery tray spacers to the tray in the countersunk holes The battery tray is attach...

Page 34: ...e canopy thumbscrews when installing the canopy Use the crosshole to tighten the canopy mount Repeat on other side If you ve purchased the Fiberglass canopy with your kit cheeked as shown or no cheeke...

Page 35: ...f the engine box for these next steps A dial indicator is ABSOLUTELY necessary to install the cooling fan to ensure a smooth running helicopter The crankshaft has a very sharp edge at the top of the t...

Page 36: ...ermissible to use a drop of CA or super glue as a form of loctite on these 4 screws On the opposite side of the engine install the fan shroud mount with 4 ea 5X12 SHCS with loctite Make sure you have...

Page 37: ...owly watching the dial and marking the LOW side of the hub With a smooth faced hammer tap down on top of the fins on the HIGH side of the assembly Don t be afraid to give it a good solid tap the check...

Page 38: ...part TOOL KIT Ultimately you should end up with your fan having less than 002 total runout as you spin the fan This should not be difficult to achieve I usually spend less than 10 minutes on this step...

Page 39: ...d using a heat gun or hair dryer Install 4 ea 3X16 SHCS through the shroud and shroud mount holes Once you have all 4 bolts in warm the entire shroud to relieve any stress on it This will help prevent...

Page 40: ...with a 4X16 SHCS and 4m washer A black can muffler is included with the Zenoah engine and a bag containing a spacer gaskets and muffler bolts Included with your Intrepid Kit is a thicker spacer which...

Page 41: ...her side of the thick spacer with the longer muffler bolts through the muffler and install it on the engine The carburetor included is a Walbro 643 which includes a pump bulb and an idle adjustment sc...

Page 42: ...p Slide the arm over the butterfly shaft Look at the angle of the arm in both the open And closed position Rotate the arm so the angle is the same in both positions Secure the arm with 2 ea 3X3 setscr...

Page 43: ...air filter base carburetor and gaskets as shown with the two bolts through the whole assy Be especially sure that the gasket between the carb and insulator block is correct with the hole in the gaske...

Page 44: ...ete Set the engine into the lower frames and loosely install 2 ea 4X16 SHCS with 4m washers through the frames into the case of the engine Also LOOSELY install 2 ea 3X8 SHCS with 3m washers through th...

Page 45: ...pliers helps to get the locknuts installed All of these bolts are left loose so you can adjust the engine up and down fore and aft to set the gear meshes later on Check the orientation of the pull sta...

Page 46: ...e LONG end of the tab into the grommet Place the servos into the frames splined shaft to the rear from the INSIDE and secure with the preferred screws If using JR servos the supplied self tapping scre...

Page 47: ...the holes in the front battery tray Set the tank in place with the cap towards the rear of the heli and mark 3 holes just behind the battery tray The tank does NOT squeeze in between the frames but si...

Page 48: ...mble the clunk line by inserting the clunk into one end of the supplied Tygon tubing Cut it with sufficient length to reach the end of the tank Alternatively a suggestion is to use a longer piece for...

Page 49: ...ure with zip ties Insert the fitting into the middle hole of the tank and secure with the third nut Be sure the tank is clean of all plastic bits from drilling and install the cap The clunk line shoul...

Page 50: ...y I like Zeal tape but understand that it may be too expensive to use in this application Some type of foam will suffice Set the tank under the battery tray and wrap the zip ties around it to secure t...

Page 51: ...on the carb This is a return line when pumping the bulb on the carb You can also use this as a Fill line from your Gas can On the third fitting install a vent line that droops down to the landing gear...

Page 52: ...The lower frame set is now ready to accept the upper frames but we have to put them together first Bag 5...

Page 53: ...es on the INSIDE of each frame half Very carefully run a bead of thin CA superglue around the flange of the bearing securing it to the frames If you get CA into the bearing it won t be any good If not...

Page 54: ...ole in the yoke Use the screw to draw the shaft into the yoke The second shaft will be a little more difficult using a ball ended driver makes it a bit easier Assemble the front transmission next noti...

Page 55: ...e up the hole If it s difficult to get it through rotate the coupler on the shaft 180 degrees and try again Install the cross pin making sure it sits flush on both sides Secure the cross pin with a 3X...

Page 56: ...ft play by pulling and pushing on the delrin coupler If you find a small amount of play then line up the OTHER hole in the pinion with the divot on the shaft and try again It is NOT necessary to insta...

Page 57: ...on of the bearing up and install 2 ea 3X35 SHCS to hold it in place Note the rear screw also goes through the front of the transmission cage Place the upper mainshaft bearing block in place also notin...

Page 58: ...ce ensuring the LONG shaft sticks out the RIGHT side The collective servo goes into the left side frame Install the plastic servo mount tabs from Bag 11 and install the servo from inside the frames wi...

Page 59: ...s together note where the servo wires exit the servo and dremel out the frames to clear the wires Put the upper frames together sliding the flanged bearings over the axles and pushing the bearing bloc...

Page 60: ...locks but do not tighten just yet As an option we offer a thrust bearing setup for the mainshaft This is intended for load carrying birds like an EB carrying an underslung camera mount 4 ea 3X8 SHCS a...

Page 61: ...Install the rear canopy mounts in the bottom of the 2 holes behind the mainshaft bearing blocks with 2 ea 3X8 SHCS and loctite Use the crosshole drilled in the canopy mount to tighten them down...

Page 62: ...Bag 11 Orient the servo with the splined shaft forward and secure with either the JR servo screws or 2 5X8 SHCS and 2 5 washers Place the forward most set of boom clamps in between the frames and put...

Page 63: ...e 3 ea 3X40 SHCS to install the tail servo mount to the frames with the screws going through the bottom hole of the boom clamps Loosely install 6 ea 3m Locknuts onto the 6 screws then we re almost rea...

Page 64: ...mainshaft and clutch system The delrin bushings are first with 2 ea 4X16 SHCS Note the steel insert and that one end has a chamfered hole the other does NOT Insert the screw into the chamfered side th...

Page 65: ...EB triple bearing block and start shaft collar The clutch bell has the liner factory installed and machined to the proper diameter If you need the liner replaced send us your clutch bell for 20 we wil...

Page 66: ...Make sure the clutch spins freely inside the clutch bell and the clutch bell spins freely inside in the triple bearing block Set this assy aside for later The main gear is machined from Delrin to be...

Page 67: ...o hub has a long and short end The long end is the TOP and is inserted into the main gear from the bottom Line up the 4 holes in the main gear and the autohub and install 4 ea 3X8 Low Head Cap screws...

Page 68: ...side up Slide the shaft up some more through the elevator yoke and install the second split collar onto the shaft stepped side UP this time chamfered side down If you have the thrust bearing block opt...

Page 69: ...it the collar They do not require loctite but they DO require a hardened Allen driver to tighten them down and loosen them without stripping the heads out Cheap sets of tools at this point are NOT you...

Page 70: ...side has a sharp edge this is the side that the large hub sits inside of Install the hub into the gear using 10 ea 2X8 SHCS installing all of them loosely then tightening each one a little bit at time...

Page 71: ...opposite each other loosely for now then install the remainder snugging them down slowly a little at a time to again prevent warping the gear Thread the 2 ea 3X10 SHCS into the two sides of the hub b...

Page 72: ...d is inserted into the gear hub from the bottom Put a dab of grease in the underside of the crown gear hub place the 10X16X1 washer in it then dab a little more grease onto the washer During an autoro...

Page 73: ...w only use it to locate the hub onto the shaft Now tighten the 2 ea 3X12 SHCS Pinch bolts securing the hub to the mainshaft Now you can go back loctite and tighten the SS in the divot Only tighten it...

Page 74: ...cure with the 4 40 SHCS Insert the top of the mainshaft through the bottom mainshaft bearing install split collars above and below the elevator yoke with the step towards the bearings then up through...

Page 75: ...hardened allen driver Tighten the upper main shaft bearing block bolts and tighten the forward bolt in the lower mainshaft bearing block Now install the clutch assy with 4 ea 3X8 SHCS with washers in...

Page 76: ...readed spacers and 10 ea 3X40 SHCS Start at the front with a threaded spacer in between the upper frames an un threaded spacer between the uppers and lowers and run a bolt through threading into the i...

Page 77: ...threaded spacer Repeat the process with another set of spacers and bolts just to the rear of the 3 servos Continue with the final 3 sets of spacers and bolts in the triangle shaped set of hole to the...

Page 78: ...motor move the engine up and down as needed to set minimal gap between the fan hub and clutch moving the engine and clutch assy forward and aft as a unit to set the gear mesh What we want as a mesh is...

Page 79: ...reinstall the 2 ea 4X16mm SHCS into the side of the motor using Red RTV as a form of loctite We use Red RTV because it withstands the heat of the engine better than loctite does Install 2 ea 3X8 SHCS...

Page 80: ...ce correct mesh is set Here again we want minimal or NO backlash as long as everything spins freely When you re happy with the mesh tighten the 3X35 SHCS bolt and 3m locknut going through the front of...

Page 81: ...nto the mainshaft and snap the elevator yoke ball links onto two of the outer balls The washout unit assembly starts with the washout arms Install 2 ea 3X7X3 flanged bearings into each arm then instal...

Page 82: ...should be able to spin freely Secure the bolt with a 3X3 setscrew inserted into the hole on the opposite side tightening it against the bolt Check for slop and free play readjust the tightness of the...

Page 83: ...he ones to the sides Look at the flybar in the pic noting the angle that it is NOT pointing straight out away from the heli This is the retarded setting and in general gives you a more stable hover an...

Page 84: ...ed swashplate timing and in the higher end radios can be adjusted electronically in a specific mode or by mixing in some aileron with elevator and elevator with aileron If you prefer to have your swas...

Page 85: ...r frames just above the collective servo and collective axle The angle plate is installed just forward of the gyro mounting plate using 2 ea 3X8 SHCS These bolts can be secured with a drop of CA super...

Page 86: ...uggest using Zeal tape available from us as an isolation from normal gasser vibrations to the gyro Mount the gyro onto the tape then use a small piece of velcro as a safety belt not too tight just eno...

Page 87: ...ve install it in the innermost hole Some or all of these arms may be black anodized Install short balls 1 in the triple bellcrank one in the single bellcrank and 2 in the elevator arm Install 2 ea lon...

Page 88: ...ll 2 ea short balls in each aileron bellcrank noting that you are making a right and a left The short balls may be silver in color Another view of the aileron bellcranks Install the 5 X 8 X 2 5 Flange...

Page 89: ...n bellcranks get 3 X16 s Using loctite thread the bolt into the popsicle stick then tighten the jamnut against the popsicle stick By loosening the jamnut and tightening or loosening the bolt you can a...

Page 90: ...t axle in the elevator yoke Secure it with a 3X8 SHCS w loctite and 3m washer into the collective axle Install a 3X4 SHCS w loctite into the short axle of the elevator yoke Install the right side Pops...

Page 91: ...e Using the same method as the aileron bellcranks set the tension of the bearings in the X arm by holding the jamnut then tightening it against the Popsicle stick to secure it When tensioned properly...

Page 92: ...it with a 3X4 SHCS with loctite and a 3m washer drawing it onto the flats of the axle Install the single bellcrank onto the lower collective axle on the right side and secure with a 3X8 SHCS with loc...

Page 93: ...te and a 3m washer Be sure the bellcranks spin freely with the axle Begin installing the aileron servo into the aileron servo mount by installing the brass or silver eyelets into the rubber grommets f...

Page 94: ...mooth of the plate oriented as shown with the splined shaft forward Secure the servo to the plate with 4 ea 2 5mm SHCS and 2 5 m washers or the JR self tapping servo screws Snug them down enough to se...

Page 95: ...d 2 ea 3m washers You only need washers on the 2 rear bolts Do NOT use loctite on these bolts but you CAN use CA Superglue as a form of loctite The plate is made from G10 which is porous and will not...

Page 96: ...mpeners allowing them to do their job of dampening the flapping motion of the rotor head system Insert the axle into the head then slide the one piece dampeners onto the axle seating them into the hea...

Page 97: ...a sharp edge the other side is somewhat rounded This is from the stamping process when it is made You want the SHARP edge facing outward when installed on the head axle This will aid in keeping the s...

Page 98: ...into place using the blade grips if only using the soft setup There are 2 sizes of bearings associated with the seesaw tube The 4X10X4 bearing 4mm ID goes into the end of the tube Do not confuse them...

Page 99: ...to the head with the milled slot facing the direction shown in the picture With a drop of loctite on the bolt insert the bearing assy into the head threading the bolt into the seesaw and drawing the b...

Page 100: ...drawing it in while tightening the bolt Now tap it in flush effectively setting both sides flush with the headblock Install 2 ea 3X5 panhead screws with loctite just above each bearing as a retainer W...

Page 101: ...h the end of the seesaw and secured with 3X4 setscrews and loctite in the short leg The setscrew sits in the milled groove of the seesaw tube to prevent the endcap from rotating Install a short ball o...

Page 102: ...ngs installed onto each side of the head axle Locate the 3 piece thrust bearings and 2 ea 5X16 SHCS and 5M washer Grease the ballcage of the thrust bearing set then install the thrust washer with the...

Page 103: ...face inwards then install the thrust washer with the SMALL ID grooved side inward Install both 5X16 SHCS bolts and washer with loctite and tighten using 2 Allen wrenches tightening against each other...

Page 104: ...the bolt into the middle hole on the pitch arm recommended This hole gives a 0 Delta offset the other two holes give a positive or negative delta offset for those so inclined to experiment Set the ten...

Page 105: ...ssed later in the manual For a standard configuration we suggest the setup as shown You will want to install the balls before attaching the pitch arm to the blade grip Attach the pitch arm to the blad...

Page 106: ...bolts alternating sides tightening a bit at a time These bolts are what actually hold the head to the mainshaft the jesus bolt is strictly for location Now go back and tighten the jesus bolt Insert th...

Page 107: ...of the flybar ensuring they are EXACTLY the same moving it in and out as necessary We do NOT put flats on the fly bar to prevent a stress riser meaning this would typically be where the flybar would...

Page 108: ...onto the flybar This will ensure proper thread length into the paddle Measure the distance between the flybar arm and the paddles making sure both sides are identical Also ensure that the paddles are...

Page 109: ...bellcrank as a template for the holes JR servos users the existing holes in the wheels are close enough for our purposes Make sure your pitch curve in the radio is set for a 0 50 100 curve meaning a s...

Page 110: ...ileron servo again centering it EXACTLY EXACTLY EXACTLY EXACTLY The first pic shows it slightly off the second pic has the wheel rotated 180 degrees and perfectly centered Here you can see the numbers...

Page 111: ...the center of the X arm bolt Do the same with the tail servo wheel rotating it until one set of holes is exactly straight up and down We HIGHLY recommend the use of the plastic servo WHEELS vs metal w...

Page 112: ...ch holes we suggest using for proper setup in a true push pull system Notice that they are OFFSET slightly from straight vertical or in the case of the elevator the angle from the X arm On the aileron...

Page 113: ...site side with loctite Next up are all the pushrods for the control system Yes there are quite a few of them but with a few simple rules it s NOT that complicated The plastic links are what are normal...

Page 114: ...ength Note that the Servo wheel balls AND the balls on the triple bellcrank are both straight up and down The linkage from the triple AND single bellcrank on the opposite side to the popsicle sticks u...

Page 115: ...centered Then use the 40mm long rod to make the linkage from the aileron bellcrank to the swashplate 57mm long center to center or 64mm long end to end Elevator servo to X arm linkage is made from th...

Page 116: ...he Flybar arms use the rods 30mm long making them 47mm center to center or 54mm end to end The washout arms should exactly horizontal From the swashplate to the bell hiller mixer use 75mm long rods ma...

Page 117: ...nter to center or 37mm end to end with a half twist and install them With both of the rods attached to the bell hiller mixer they should also be exactly level For Pitch setup purposes we offer a flyba...

Page 118: ...collective stick at half verify that the pitch on the blades is at 0 degrees If not go back and find which bellcrank is NOT exactly level horizontal or vertical You should also be able to achieve 12 d...

Page 119: ...ed Boom Tail instructions Building the EB tail starts with the dogbone pin and a 3X4 Setscrew With the pin in place use loctite and secure the pin with the setscrew coming in through the rear of the d...

Page 120: ...other at 17 Cut the ends as square as possible then clean up any burrs or rough edges The complete TT system includes the gearbox 4 ea collars a bearing carrier with coupler shaft and the dogbone Asse...

Page 121: ...the collar around it In all cases seat the arrow shaft all the way to the shoulder of the inner shaft and secure with ONE 3X3 setscrew for the time being At each collar pick one setscrew hole and dri...

Page 122: ...divot installing a setscrew IN the divot followed by the other 2 setscrews This system effectively pins the TT together as a unit preventing slippage as long as your divot is sufficient to seat the s...

Page 123: ...degrees and try again With the 2 ea 3X4 SHCS you removed earlier you DID remove them earlier didn t you loctite them back in to the gearbox getting both bolts started first THEN tightening them both u...

Page 124: ...ce the boom into the clamps tail output shaft AWAY from the fin slide the other half of the clamps onto the bolts and secure with 4 ea 3m locknuts These nuts again do NOT require a lot of torque not i...

Page 125: ...p with 2 ea 3X8 SHCS A drop of CA superglue will help keep these bolts secure Slide the horizontal fin and clamp onto the boom back towards the vertical fin It will get secured later with the boom sup...

Page 126: ...s it makes a good lubricant THEN totally evaporates locking the bearing carriers into place in the boom Mark your wooden dowel at 10 this is for the fwd bearing carrier Mark it again 12 farther back o...

Page 127: ...the way into the boom to the rear or 22 mark Lubricate the fwd bearing carrier with Windex and install it into the boom as well It is HIGHLY suggested to either let the Windex dry or use a rag to cle...

Page 128: ...ure the bearing carriers in place in the Boom If you ever need to remove the bearing carriers squirt more Windex into the boom and push them out with the wooden dowel Cut 1 off of one end of the arrow...

Page 129: ...inserting the pin centering it and securing it with a 3X4 SS and loctite installed from inside the dogbone Insert the dogbone into one end of the arrow shaft and slide one collar over both pieces Inst...

Page 130: ...a divot Disassemble the joint and inspect your divot You want it deep enough that the setscrew will sit into it when assembled Reassemble and install a 3X3 setscrew with loctite in the hole with the...

Page 131: ...through the bearing carriers Push the TT all the way through until the rear off the TT sticks out the back of the boom Slide the remaining Collar over the TT the insert the input shaft of the tail ge...

Page 132: ...e divot to ensure it s deep enough for the setscrew to set into it Reassemble the parts and loctite a 3X3 setscrew into the hole with the divot then the remaining 2 setscrews Remove the 2 ea 3X4 SHCS...

Page 133: ...ide the horizontal fin clamp onto the boom These instructions apply to BOTH Standard and EB Versions Insert the tail boom into the boom clamps at the rear of the heli pushing it ALL the way in ensurin...

Page 134: ...uts and bolts going through the boom clamps It is NOT necessary to close the gap on the clamps nor is it necessary to put tape sandpaper or screws into the boom to hold it in place Assemble the boom s...

Page 135: ...rear of the lower frames with 2ea 3X12 SHCS 3m washers and 3m Locknuts Secure the rear of the boom supports with a 3X35 SHCS 2 ea 3m washers and a 3m locknut but don t tighten the bolt just yet Insta...

Page 136: ...tical fin components if not already installed 4 ea 3X30 SHCS 4 ea 3m locknuts and 2 sets of boom clamps Note the orientation of the fin place the 4 bolts in the 4 holes and slide 2 of the boom clamps...

Page 137: ...and tighten the 4 ea 3m locknuts onto the bolts Again it is NOT necessary to close the gap between the clamps only to tighten them Assemble the tail pitch bellcrank by installing 2 ea 3X7X3 flanged b...

Page 138: ...r down slightly to achieve this Install the special bolt a 3X12 w 6mm shoulder then place 2 ea brass washers on the bolt Install a medium ball on to the bellcrank For most gyro applications the inner...

Page 139: ...il pitch slider is a preassembled unit slide it onto the output shaft making sure to insert the ball into the delrin cup Operate the mechanism by moving the bellcrank by hand making sure the operation...

Page 140: ...shaft will also help Check the fit of the ball into the delrin cup and ream as necessary Proper operation here will greatly affect how well your tail rotor gyro servo system works The tail rotor hub...

Page 141: ...t Using only one setscrew IS more secure than 2 setscrews 180 degrees apart in this application The aluminum tail blade grips already have the radial bearings installed so begin by inserting the 4X4 s...

Page 142: ...ausing servos to overheat tail wags sticking etc The tail blade grips and associated hardware must be installed in the proper order for proper operation note the 10mm OD spacer installed BEFORE the th...

Page 143: ...greased ball cage then the small inner diameter thrust bearing washer Secure the assy with a 3X6 SHCS and a 3m washer with loctite Do not over torque this bolt it is not necessary Repeat for opposite...

Page 144: ...fication in trimming off the ribs off of each side and cutting them down to 17mm long for the Standard Gasser Magnum gearbox or 15mm for the EB HD gearbox Thread the links all the way onto the eyelets...

Page 145: ...in the pics We use a leading edge control on our grips The tail blades included in your kit are from KB Dream Designs and may vary slightly in design and color from the picture The tail blades are ins...

Page 146: ...knut Only tighten enough to barely hold the blades in place Not the direction of the tail blades leading edge The tail pushrod is made from a carbon fiber rod Assemble the aluminum ends with a 3X18 SH...

Page 147: ...the nut sufficiently to prevent the bolt from turning and thread the ball link onto the stud about half way down Assemble the other end the same way then glue ONE end on to the carbon fiber rod using...

Page 148: ...d assy When measuring for this make sure the tail pitch bell crank is at 90 degrees and the tail pitch slider is centered on the output shaft Glue the second end onto the cut carbon fiber rod with JB...

Page 149: ...nly put a small amount of tension on the pushrod with the velcro This velcro support will help to keep the pushrod from vibrating like a banjo string Tuck the velcro strap up under the front of the ho...

Page 150: ...e boom clamp bolt Now carefully spin the tail blades around until the opposite blade comes near the same bolt If they are not the same distance from the bolt as in the 2nd picture then adjust the leng...

Page 151: ...ection Tighten the blades enough so that if you lay the heli on it s side and shake it the blade will not move in the grips This is especially important with the EB using long blades If the blades are...

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