Helicopter Kit Build Notes for Basic Assembly

The following are intended as a guide to building Model helicopters.

They are designed to supplement the Kit Instructions where detail is missing.

General Tips

• The instructions show the number and length of screws and bolts exactly.
• Never assume that the instructions are wrong.
• Do not substitute anything; use only what the kit provides.
• If something doesn’t fit then try again, or ask for help.
• Do not drill out holes or alter parts in any way.
• The correct grade of Loctite is "Screwlock" , not "Studlock"

Engine

• Typically the instructions show the fan hub being fitted to the engine crankshaft and being tightened with a socket. Do NOT put anything into the Exhaust or Glowplug opening to lock the crankshaft!
• To lock the crankshaft while fitting the fan hub, the following is recommended:
• Remove the 2 Carburettor fixing screws carefully and lift out the carburettor.
• Place the handle of an old toothbrush or similar non-metal part through the carburettor mounting hole into the crankshaft cutout. (rotate the shaft to line-up the holes)
• Fit the fan hub and collets on the crankshaft.
• It is usual to leave the special OS Black washer in place at the front of engine bearing.
• Apply a little Loctite "Screwlock" to the nut threads.
• Apply a suitable washer inside the fan hub before the nut.
• Use a 10 or 11mm Socket as needed to tighten the Nut firmly and carefully. Under no condition should the engine be mounted in a vice, as this WILL distort the crankcase. Instead, wrap a clean cloth around the engine and hold it firmly in one hand while tightening the nut, with medium force.
• Remove Toothbrush or other from the carburettor mounting hole and ensure any shavings, chips or other particulate matter is removed.
• Refit Carburettor with Fuel nipple facing engine and ensure that any O-ring is refitted and compressed to form a proper seal.

Servos

• When fitting the servos refer to the Radio Instructions and specific Helicopter Manual.
• For each servo fit 4 x Rubber grommets and then 4 x Brass sleeves with flanged ends underneath the servos.
• Use only the 20 x Special screws and washers supplied in the Helicopter Kit when fixing.
• Do not use the woodscrews supplied with the Radio gear.

Blades

• The blades are best left alone if you do not have the correct balancing equipment.
• They will be balanced F.O.C when the Kit is being checked over.

Gyro / Tail Control

• The set up of the Gyro is critical both in Gain and direction.
• The actual settings and procedures vary from one Gyro type to another.
• Use the supplied tape only.
• If the set up is wrong then the helicopter will spin continuously and out of control on "take off".

Rotor Head Assembly

• Pay particular attention to the correct layout of the bearings used in the rotor head.
• The Thrust bearings (if used) must be assembled with the smaller Diameter hole to the outside.
• Check for freedom of movement on all the individual levers as the kit proceeds.
• Observe the correct orientation of the ball and socket assemblies at the control rod/lever ends.
• The 2mm Bolts should be tightened sufficiently to lock the ball securely.

Engine Starting

• The engine should NEVER be started or run before fitting to the helicopter!
• On no account should the engine be started until a competent person has checked the helicopter controls, the radio setup and the throttle servo direction!
• During subsequent maintenance or repair activities the engine must NEVER be restarted without rechecking the above Items.
• The engine can NOT be started for the FIRST time or RUN-IN with the main blades attached! Running in requires a set of "dummy" blades and needs to be carried out by a competent person.
• The "tuning" of the engine can only be carried out using test equipment fitted for this purpose.
• Ensure the "throttle-cut" switch or "Trim" on the transmitter allows the throttle to be closed fully and kill the engine under all conditions!
• The engine can never be run above idle without the main rotor blades attached!