Crash Damaged Blade 400 - My First Heli Project

[Slyster]

Nice hovering! I crashed yesterday.. mostly due to poor lighting (well I hope that was it) too around 4 hours to fix.. but my first major repair so 1/2 that time was school... next time will be easier. Had to assemble the feathering shafts from scratch.. I can't tel you how much this picture helped. Found this somewhere I can't remember. The link is in the B400 bible.

[ted_wears_a_hat]

Thanks Slyster, good luck with your rebuild.

The image is from RCGroups, a heli flyer called RHash I believe, but could be wrong. Here is an additional one of my own that helps me put part diagram to reality.

http://www.helifreak.com/picture.php?albumid=620&pictureid=5615

I got her rebuilt in an hour or so but have a problem now trying to spin her up, I think the one way bearing may be installed wrong, I will check it over at lunch.

Have a good day all.

[Ed Zachary]

Thanks for the graphics, guys!

Looking at Ted's pic, I realize that the thrust bearing that was threadlocked to the flybar at the factory in my junkbox special had the innermost cup washer installed backwards (with the "groove" facing out).

I also noticed the inside diameter of the washer at the screw is substantially smaller than that of the other parts in the picture. The ID of the washer on my feathering shaft is large enough for it to become sort of swaged onto the end of the feathering shaft.

Sheesh...

[ted_wears_a_hat]

Hola Ed. :thumbup:

Glad they are useful, remember as well to put the open face of the bearings in the thrust bearing facing into the main shaft and also note that one of the outer races has a slightly smaller inner diameter than the other. This should go on the blade side of the thrust bearing. Keeps lubricant in against the centrifugal force of the spinning blades. Thanks Redfire for the original heads up on that one. :thumbup:

Keep on flying.

Fixed her up after the crash and ran her up. The blades wouldn't spin at all just kind of whir once, then stop, whir once, then stop. Sort of like a car not starting. Initially I thought I might have installed the gear wrong but that seemed fine so I have slacked off the belt and she runs fine. There is still what sounds like a mild slip, almost a "whirp" before she fires up but once up to speed all seems ok. Slightly more than before but not bad enough to concern me. I will give her a full once over when I get a spare mo but right now is just busy busy busy. I need to reset up the tail in rate as changing the boom as altered the setting enough to make 6 left beeps of rudder trim to get rate close. Even then the tail is tick ticking like a slightly deranged clock!

I noticed there is some odd interaction with throttle in the tail when on the bench, if you give a load of throttle the tail servo gives a little twitch. I was able to duplicate it a couple of times and then it stopped doing it. I think, I'm going to switch out the tail servo with another spare DSP75 for now whilst I test the current one.

Again schedule dictated that I didn't have time to set up the tail properly but I needed a fix so flew her trimmed up in rate. It's good practise I suppose. I also didn't have a spare set of blades (they were here when I got back from work though) so I parcel taped up the least damaged of the two sets of damaged blades I have, sorted cofg and balanced them. They make a bit of a racket and lift is definitely down but they got ol' Vera up flying so all good. The swash also needs a little adjustment but again, there's only 24 hours in a day.

Vid of me hovering in rate with blades that look like they are sponsored by parcel force!!

LilDlhBd_fU

:happyd

[Falcon4]

took mine out on sunday for a while, only my 5th time...due to weather being so crap here...first hover ok..landed ok...2nd time hover , brought her down at an angle....first repair at the field, main shaft & spindle..
3rd time..she got away from me on the hover , so decided to put into practise what ive been doin on the sim...as u can guess after 3 mins in the air took a wrong turn straight into the top of a tree, branches and all....had to shake the tree to get it down....main shaft and feather again..lucky i thought!!!
another repair on site. 4th flight..nice hover great...
5th flight gust of wind..tail boom, main, feather shaft.. took it home..lol
sorry guys no vid as no tv card to upload, but getting a new cam corder, daughter only took vid of last 2..
need to find away of seeing far away..lol

[ted_wears_a_hat]

Tell me about it! The weather has been abysmal and I know what you mean about gusty wind. Sunday and Monday were lovely days but the wind was really killing me.

Sounds like you need to just take it slowly. I have spent at least 5 out of every 7 packs hovering in a limited sized space in order to force myself to keep it close and in control. And hey, as long as you're having fun that's what counts the most.

Keep on flying Falcon. When it clicks the B400 will be a bird of prey herself.

:YeaBaby::thumbup:

[Falcon4]

its getting there ted...this bird has some power and distance..loving every min of it bud...still need the practise on the sim too...getting very adept at repairing it tho...my LHS gets most of the stuff i need mostly in 2 days..but hey its fun

[ted_wears_a_hat]

Damn right Falcon. She sure gets away quick when taken off her lead. Lots of speed and plenty of power. Keep on keeping on. :thumbup:

[ted_wears_a_hat]

First big crash today. :shock:

Must say though still got a big grin on my face regardless. :thumbup:

Found a great new place to fly, massive private field and had a good day flying, started with some hovering. First pack was tail in eye level, then tail in high, then land. Repeat. Second pack, tail in, rotate to 45, hold. Rotate to tail in then 45 the other side. Land. Repeat. Charge. Third pack hover, move along a line 25 yards, hover, rotate to 45, hold, rotate to tail in. Return. Land. Repeat but opposite side 45. Fourth pack, hover S shaped line, hover, return straight. Land. Repeat but faster, over correct, get it back in control but a long way out, try and get her back toward you half succeed but misjudge speed and drill it tail first into the ground 50 yards out.

Must have gone in hard as the boom has snapped off in the frame and actually sheared off enough of the plastic to make me wonder if there will be enough purchase with a new boom. I have a spare frame so might use this as an excuse to transfer everything.

http://www.helifreak.com/picture.php?albumid=967&pictureid=6896

http://www.helifreak.com/picture.php?albumid=967&pictureid=6897

Total damage:

Boom - Write off - In stock at Ted's Blade emporium. :YeaBaby:
Tailer slider - Possible write off, might be thin enough to get back into shape - Out of stock at Ted's and Fast Lad. Will phone others on Monday.
Main gear - Write off, only one two missing but snags on the pinion - Out of stock at Ted's but in stock at Fast Lad.
Main Shaft - Mild damage but will write off as I have plenty in stock.
Feathering Shaft - Write off but surprising little damage given how weak they are reported to be - In stock at Ted's.
Tail servo [SDSP 75] - Response is normal one way but snags the other, I haven't
opened it yet but it sounds like gear damage - Gear sets and spare servo in stock at Ted's.
Servo Boom Mount - Sheared! Want to boom mount the servo any for better weight distribution so may take this chance to get a different set.
Horizontal Fin - Smashed - Have a B400 one but will need to order 450 ones.
Main frame - Possibly - In stock at Ted's!

I won't get a chance to do it til next week so it'll be sim time only this week.

Take care all; hope you are all flying high.

[Falcon4]

Damm Ted

seems it got away from u bud, i got bit by mine earlier today, dont try this at home guys..it hurts a little

was setting up, spun her up on the table at home with just the flybar on, someting must have come off, started to shake on the table..came of the table so dumb idiot here tried to save it without turning it off...result, see the pic

[LockMD]

Damm Ted

seems it got away from u bud, i got bit by mine earlier today, dont try this at home guys..it hurts a little

was setting up, spun her up on the table at home with just the flybar on, someting must have come off, started to shake on the table..came of the table so dumb idiot here tried to save it without turning it off...result, see the pic



OUCH!

Question is........did you save the bird?

[Falcon4]

No Lock i didnt, got a broken swash plate..must have fell right on it to break it..gonna have to look for all metal parts on this head, just to easy to break things

[ted_wears_a_hat]

Ouch Falcon!

Regarding the swash plate, Twister 3d Storm parts seem interchangeable, if so they have a CNC swash (7th item down):

http://www.modelhelicopters.co.uk/acatalog/HeliSprs_TwisterStorm.html

I don't want to go fully CNC because of weight concerns but can see a CNC swash being useful if my alu and composite one begins to show any slop (hasn't at all yet).

[Falcon4]

I got my LHS getting another one, plastic one from horizon, might take a trip to midland helis the weekend...pay day.

[ted_wears_a_hat]

^ I know what you mean. Same for me. I hate this last week!

Anyway; pictorial damage summary......

All broken kit:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage001-all.jpg

Main gear:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage002-maingear.jpg

Head (flybar and feathering shaft):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage003-bentflybar.jpg

Boom (initial strike location):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage004-boominitialstrikepoint.jpg

Boom (shear point):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage005-boomsheared.jpg

Both Blades:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage006-blades.jpg

First Blade to hit:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage007-firstbladetohit.jpg

Second blade to hit (note the minimal damage):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage008-secondbladetohit.jpg

Broken landing gear tab:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage009-shearedtab.jpg

Tail box damage:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/damage010-tailboxdamage.jpg

Video of bent feathering shaft:
WVf2pByXNXw

Video of bent tail output shaft:
K0GLRmgmiAw

[ted_wears_a_hat]

I have everything I need in stock apart from:


Tail Servo Boom Mount - Stock Code EFLH1458
TWISTER 3D STORM TAIL ROTOR OUTPUT SHAFT (2) - Stock Code 6602412
TWISTER 3D STORM MAIN GEAR & AUTO BEARING - Stock Code 6602368

I also think I will pick up a new motor and mount to avoid having to fiddle too much getting the motor off the mount to change the pinion (see: http://www.helifreak.com/showthread.php?t=81028 for details).

Parts:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/sparestofix001-all.jpg
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/sparestofix001-eflite-1.jpg

I have stripped everything (mechanical and electrical) off the old air frame and started the rebuild, everything mechanical is in the new airframe so I can visualise it. I will have to wait for my new bits to arrive to go any further.

Cut away of airframe with gear etc
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/RebuiltFrame001.jpg

There's a heli in here somewhere:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/Restoftheelectronics001.jpg

Aww Vera mkI (now retired - with honours):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/OldFrame001.jpg

Rebuilt head:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/CompletedHead.jpg

I'm glad I effectively bought this heli as a kit as it was pretty comfortable taking everything apart and rebuilding. It's a simple but very effective frame design.

I was playing around with the empty frame and it is super rigid, with the motor mount and tail gear mount installed the only real flex (without a lot of force) is in the battery tray. An extra brace through there would be a good thing for the B400 V2. I also reckon V2 should have a slightly extended tail box to allow for better purchase on the boom as well as the ability to mount the gyro a little further from the rear cyclic servos. The only problem may be additional potential gyro damage in a boom strike. I'm not really sure how much tolerance there is at full pitch and cyclic.

Take care all.

[Falcon4]

nice to see u have the patience ted...if u have the frame in 2 halfs at the mo, would it be worth marking the outside of where the elevator arm would sit at 90 deg ...just to make it easier when setting up?

[ted_wears_a_hat]

All fixed up! Gotta rush going to go flying.. :thumbup:

Swash level at midstick:
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/swashlevellingtool002-midstick.jpg

Swash at low stick (some interaction):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/swashlevellingtool001-lowstick.jpg

Swash at full stick (some interaction):
http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/swashlevellingtool003-fullstick.jpg

Some finished pics:

http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/fixedup002.jpg

http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Vera%20-%20B400%20Crash%20Rebuild/fixedup001.jpg

[xpower180]

'appy flyin' Ted :thumbup:

[dpearcy]

I would get rid of those servos....I crashed mine last week and it was not pilot error. It was a malfunction on the servo. You can see alot of problems out there on the servos. I believe they are only good for a few months of flying....:thumbdown:

[ted_wears_a_hat]

Thanks xpower, definitely is good to fly.

Hola dpearcy, servo's have already been changed for HS-65mg I never got to fly the stock servos as I bought a crash damaged second hand blade which had servo's stripped.

Flew 3 packs today, I still only have a single pack so 40 minute breaks between flights but still feeling some progress.

I videoed all three and have even added music I(and a couple of piros!) for you kind folks. Almost lost it on the exit to a piro in the last flight but saved it with a swing swing back in the right direction, I guess that was my first bank turn!

Flight 36:
vWelfd0Znlc

Flight 37:
n9tomjNDkmE

Flight 38:
K0WOg0yVfu4

[ted_wears_a_hat]

F**king flytippers!

Stupid bloody lazy f**ks that can't be bothered to go to a tip or pay for their rubble to be diposed.

I HATE THEM.

http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Picture1.jpg

http://i326.photobucket.com/albums/k431/ted_wears_a_hat/Picture2.jpg

[BennyTRD]

Hey Ted, how much trimming did you have to do to get the HS-65's in? Looking at a set for cyclic. Thanks.

[mongo56]

Let me answer that. I bet Ted's busy as always ;)
The elevator servo is a straight fit. You'll have to grind the servo housing for the pitch and aileron servo a bit. I went toward the main shaft and on the bottom (less than 1mm should do the trick).

[BennyTRD]

Thanks man. Sounds like a no brainer.