Warped fan--how are people fixing it?

[Gscott]

My original fan was warped and cost me 2 governor magnets and countless hours trying to resolve it. I decided to purchase a new one from ReadyHeli and it showed up worse than the first one. Ladt night I tried the boiling trick. I boiled the fan for 5 minutes and then clamped it between 2 pieces of plywood and let it cool. Last night after I removed it from the plywood it was still a little warped but much better. This morning it's back to being pretty badly warped. I can't get Align to respond to my emails or voice mails and I'm not going to keep paying $20 for a new one hoping it's not warped. How are others fixing this? Until this is resolved the heli is grounded. If you are listening Align, this needs to be resolved ASAP.

[tamiyanut]

Sounds like were both experienceing the same problem. I found that if I over tightened the screws on the fan I would get a nasty warp, but if I just tightened it a little past snug it wouldn't be so bad. :(

Keep us updated!

[Gscott]

I wish that was my issue. I tested my fan on a flat granite counter right out of the package and I can rock it back and forth it's so warped.

[Ticidytoc]

I would boil the fan , remove from water after boiling and while still warm place it on your granite counter with a flat weight and let it cool. This should help get it where it will work if it is as warped as you say.

Is better for the plastic if the temps come down with the water, so if you have some way to let it cool with the water while keeping it flat i would opt for this.

The fan is thin, this makes it light, so if you crank down on the screws it will warp. Keep the hall sensor far enough away so that it will not touch the magnets, mine is at least 2-3mm away from the magnets and the gov. still picks them up.

[EricW]

Not good to hear this Fan problem so often.
They probably have produced many warped fans when i look at the fact that you bought a new one that was also warped.
Would be a big coincidence if they came from the same production batch.
To me it seems they have a bad or none existing quality control on that part.
Fans are very complicated parts to make, have seen the production/quality-control of vacuum cleaner fans from close-by.
The proper form, fit and size depends on many production parameters that have to be right (optimized)and monitored during production.
Once a fan is ejected from the injection-mould it takes at least 12-24 hours before it reaches it's definite form, fit and size.

When done properly, good engineering, and by a experienced injection-moulder I still would go for a plastic fan instead of a aluminium one.

Edit:
I looked at the photograph of the fan and see that the fan base plate is pretty thin....would have been better to make it a bit thicker.
Maybe it's possible to epoxy (under pressure) a aluminium plate (1mm) to the base plate??

When trying to relax plastic:
Take two plates (pref. aluminium or steel) with four holes and four bolts to clamp the fan between.
put it in a pan with almost boiling water (>80º.C or 176ºF is sufficient), make sure it's completely warmed through and through, and let it cool slowly, in the water is a good option.

Eric

[Mercuriell]

I have 3 fans and all have been perfectly level - EricW post interesting - maybe you got a bad batch (late Friday pm maybe :roll: ) but you should return them to your supplier and ask for a replacement.

[creightoncarr]

My kit arrived Friday and though my fan was not perfect, it was perfectly acceptable. By tightening the four bolts holding it to the collet different amounts it was easy enough to get it pretty flat. I then had plenty of room inside the fan shroud to position it without interference.

I did find out the hard way though that one of my aluminum engine mounts blocks was not pre-threaded. I haven't been able to find that part available yet. Until I can get a tap and thread it for a larger bolt I stuck with three-point mounting for the engine. I ran a couple of tanks through it this afternoon with no problems in that regard so far. Even during the break-in I'm amazed at how quick the 600N is. I never got around to flying the 600E on anything other than 6S with the XL motor, but the 600N is every bit as powerful and nimble as my 600E.