ULTIMATE MOD OF THE SHOGUN FRAME (and one Walkera part)

[borneobear]

Now on to the anti-rotation bracket.
Considering its a simple static structure, I didn't expect it to give so much trouble. Well, it did.
First, its location had to be JUST right, so that it could hold on to the swash extended link, at ANY pitch. On top of that, it had to clear the movement of the servo underneath. After I had gotten this two right, I found the fly bar rod could hit the top:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0527.jpg

I'd say of all the parts going into this mod, installing the anti-rotation bracket was the hardest.

[borneobear]

Well, to solve this, I cut off the top and rejoined it lower down. I used CA and nylon fibres to rejoin the two.

http://i40.photobucket.com/albums/e218/borneobear/DSCF0538.jpg

[borneobear]

Whereas the bottom had to be cut/filed out a ensure free elevator movement at maximum negative pitch:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0540.jpg

[borneobear]

All in, the anti-rotation bracket took the longest to do - and IMHO the most difficult part of this CCPM conversion.

[borneobear]

Still with the anti-rotation bracket - I drilled a hole on the bracket support to reduce weight and to enable easy access to the servo arm screw:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0539.jpg


http://i40.photobucket.com/albums/e218/borneobear/DSCF0561.jpg

(Additional holes were also drilled on the frame itself during this time, mainly to reduce weight).

[borneobear]

to be continued

[borneobear]

Well on with the Pitch and Aileron controls. I had to buy another set of the push pull arm from xmseller:
http://cgi.ebay.com/zoom-zap-shogun-400-CNC-7075-PUSH-pull-precision-arm_W0QQitemZ250053489098QQihZ015QQcategoryZ2563QQ tcZphotoQQcmdZViewItem
http://i40.photobucket.com/albums/e218/borneobear/6a_1.jpg

[borneobear]

I therefore had two sets of this push pull arm to connect my servo arms to the HS1111 swash plate:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0535.jpg

[borneobear]

Positioning of the ball links for this push pull arm - (as well as with the elevator ball link) - is exactly under the ball links of the swash plate.

[borneobear]

This is the best photo to illustrate the vertical positioning of the ball links to the swash plate - as best I could all are set at 90 degrees at zero pitch, and seen from above, the arm ball link to swash ball links are directly under each other:

http://i40.photobucket.com/albums/e218/borneobear/vert.jpg

[borneobear]

To get this ball link positions, AND to maximize up/down movement of the wash plate, the longer part of the push pull arm (yellow line) is used:

http://i40.photobucket.com/albums/e218/borneobear/adscf0530w.jpg

And to my surprise, the mounting (arrow) to get it spot on was exactly in the middle of the frame as shown above.

[borneobear]

Another view, where the mounting screws are placed in the middle - directly above the original bearing mounts (arrow) of the now un-used elevator see-saw:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0532.jpg

Placing the push-pull in this location also clears it comfortably away from the rotating tail drive (yellow line).

[borneobear]

And therefore, this is the full servo arm and ball link set up to the CCPM swash plate:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0558.jpg

I found the third hole on the HS 65 servo arm (arrow) to be the best position to maximize swash plate movement and get +10 / -10 pitch.

[borneobear]

The only other mod required is the mounting to the canopy and cutting out a small portion of the canopy to cater for the push-pull link movement:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0571.jpg

http://i40.photobucket.com/albums/e218/borneobear/DSCF0572.jpg

[borneobear]

The canopy mounting (red arrows) is moved down to an existing aluminum spacer (black arrow). The mounts were basically just screwed on:

http://i40.photobucket.com/albums/e218/borneobear/aadscf0558.jpg

It still gave good support to the canopy with no issues in flight. The nut and bolt at the bottom of the canopy remains as previously:

http://i40.photobucket.com/albums/e218/borneobear/aadscf0558aa.jpg

[borneobear]

Well, THATS IT!.

CCPM is the last major mod for this heli.
And after flying with CCPM the past 1 week, I can't see myself ever going back to mechanical mixing. There's just no comparison. Handling, pitch control (e.i. altitude control), predictability during flight - are all just amazing with the CCPM set up.

I probably even lost a few precious grams due to the conversion.

WORTH EVERY MINUTE (and $$) I SPENT ON IT!!!

Good luck and Happy flying! :mrgreen:

[borneobear]

Well... its been a while.
I've been bashing the CCPM set up quite a bit. Still love the stability. I did encounter one issue with the set up though. On one of my looping flights, I suddenly lost control of the heli. It was still flyable but barely!
When it got down (no crash!), this is what I found:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0597.jpg
An over extension of Pitch link!

[borneobear]

Here's a close up:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0600.jpg

There wasn't total lost of control as the servo could still move the push pull arm.

[borneobear]

I fixed this over extension by limiting the servo link using a long screw I got from one of my old servos:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0602.jpg

[borneobear]

This limiting screw had to be placed (and bent) so that it contacts the servo link at exactly where its movement is maximum (during max pitch and max aileron):

http://i40.photobucket.com/albums/e218/borneobear/DSCF0601.jpg

[borneobear]

With this screw in place, I've never had an over extension of the Pitch servo link anymore!!
http://i40.photobucket.com/albums/e218/borneobear/DSCF0604.jpg

Curiously, I don't face this problem on the Aileron servo side. Dunno. :dontknow
All the better. :D

[borneobear]

To clearify, this is my servo arrangement, as per Futaba receiver's requirement:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0669ss.jpg

[borneobear]

Right. Now for some blings. I bought this really cool alum canopy mounts from WATTSUPRC:

http://i40.photobucket.com/albums/e218/borneobear/UGT104_1.jpg

http://www.wattsuprc.com.au/product_detail.asp?pid=UGT104

This is the "before" pic:

http://i40.photobucket.com/albums/e218/borneobear/aadscf0558.jpg

And the "after", where the mount is basically just screwed on:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0613canopy1.jpg

[borneobear]

A very nice bling:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0613canopy2.jpg

But I later found out that the mounting screw is very soft (arrow below):
http://i40.photobucket.com/albums/e218/borneobear/ugt104_1qq.jpg

They broke off after only a few flights (coudn't carry the battery weight).

[borneobear]

To fix this, I first filed the mounting surfaces flat, followed by drilling a 3 mm hole:

http://i40.photobucket.com/albums/e218/borneobear/DSCF0613canopy4.jpg