Rave Ballistic 635 Build

[Freeskiken]

Well I started to rebuild a Ballistic 700 I bought used. I decided since the frames on the 700 were not very good, cracked, damaged edges, worn spot by the motor. I bought new frames etc. and am going to build it as a 635.

I replaced the frames tonight. This is a awesome helicopter ! After assembling the frames you realize how great this helicopter is designed. The main frame is so light and strong, simple design, not many parts.

I bought a custom wound Pyro 700-52 motor, Kontronic 120 HV ESC. I will use the internal BEC and BD3SX.

I added washers inside one side of the frame so the battery tray slids in and out nice and smooth. I like using the tray at the back for electronics. I will post some pictures tomorrow.

[PeteStewardson]

What blades are you thinking of running?

I've not flown my Ballistic for ages, I really need to buy some more packs. I did a quick tally of spares last night and I have an un-built 635 kit, 2 ballistic conversion kits ( good for frames and canopy plus other bits. ) A spare set of 635 frames, and a whole load of other spares. I have enough parts to build 2 more complete Ballistics, and still have spare parts

[Freeskiken]

I will be using Radix 625 main blades.

[PeteStewardson]

Quite jealous of you guys over there being able to get CYE products so readily. In the UK we're having the same supply issues with Radix blades as Rave helis

[GimpyGolden]

Gonna rip with that motor and 625's. I ran it in an E5-S for a while at 2300 and 15* pitch.
Fast as anything, only limit was the packs.
Let me know what ya think once you get it flying.

[Freeskiken]

[QUOTE=GimpyGolden;6395540]Gonna rip with that motor and 625's. I ran it in an E5-S for a while at 2300 and 15* pitch.
Fast as anything, only limit was the packs.
Let me know what ya think once you get it flying.[/QUOTE)

I will let you know. I am excited to get it done and try out that motor. Should be fun. Thanks again.

[pctomlin]

Sounds like a sweet setup for a 635.

[Freeskiken]

This is how it starts. A 700 frame. Some damage but you cant see it in the picture.

Removed the motor, took the frame apart.

[Freeskiken]

Here is the main 635 frame so far. Structure is so strong and light.

Reassembled the frame, replaced the lower main shaft bearing. It was rough or notchy.

[Freeskiken]

I finally received the new canopy for my 635. It is awesome !! Sick Canopy does a great job.

[Freeskiken]

I was building the tail section today.

For the boom. I sanded the plastic bushings to fit in each end of the boom. Other wise they are very tight fit and you can't get them out. It worked better to use a dremel and a 80 grit sanding flapper wheel. Then cleaned it up with emery cloth. Worked very well.

I am using the metal gears from the 700 boom. The vertical fin that I bought with the used 700 is cracked. So I ordered some new parts today. I epoxied the vertical fin for now.

I glued the bearings on the torque tube but I got one bearing on the long side out by 10mm. I dont think it will cause any problems ? Instead of 208mm I am at about 218mm.

[Jeffwrecks]

Nice canopy, should be able to see that one very well.

I have metal gears on my 700, they should work well on your 635. I use marine bearing grease because that is what I have and the only thing that bothers me personally with the metal gears is that they do sling grease so I will probably replace them with plastic gears, if I ever have to. Your 635 should be a beast!

I wouldn't imagine the bearing off by a few mm would cause any trouble.

[Freeskiken]

Thanks, it should be very visible. One of the nicest ones I have had built.

I use Permatex Ultra Slick Extreme Sport Synthetic grease, Power Sport All Weather Formula. (I had the name wrong before on the post.) As long as I am careful to not put too much on it doesn't fly around on everything around it.

[Nige]

Can anyone tell the length of the 635 boom?

I fancy shortening my 700 and trying it with a spare 4036-560 and 630 blades.

[Freeskiken]

Originally Posted by Nige

Can anyone tell the length of the 635 boom?

I fancy shortening my 700 and trying it with a spare 4036-560 and 630 blades.

The 635 boom is 29 15/32" or 748.5 mm long. Just you have to make slots on the end you cut off to fit the bushings for the torque tube. Also a hole just past the slot. Or I guess you could sand the ridges off on the bushings and just make the holes to pin the boom.

[Nige]

Thank you

[Freeskiken]

I got the boom and tail section built and into the frame tonight. Started to install it into the frame and had to take it out again. One of the hex spacers in the plastic tail box was stripped. (Used) Replaced it and put it back together.

Added plastic cross brace behind the motor. It will stiffin the frame.

[Freeskiken]

Another picture. Quick pictures just with my IPad. They aren't as good. It's wierd that on the IPad these picture are right side up ? If you click on the picture the second time they load right side up ?

I am not making it the lightest it could be because I added the ESC tray and metal spiral gears but I like those features. The metal tail gears are awesome.

[pctomlin]

Looks like it is going well. I am in almost the same spot with the Ballistic 700. Servos mounted in frame, initial settings in TotalG, ESC programmed and initial motor test run. Waiting on a new motor shaft because the previous owner cut it down and it is too short to engage the support bearing in the motor mount. Received a set of main blades and a twelve tooth pinion from Curtis today. My order from Progressive shipped today so hopefully I am completing the wiring on Friday and electronics setup this weekend. Hoping to have it ready to fly by the 23rd. Will post some pictures when done with mine, keep us posted on your progress.

[Freeskiken]

Originally Posted by pctomlin

Looks like it is going well. I am in almost the same spot with the Ballistic 700. Servos mounted in frame, initial settings in TotalG, ESC programmed and initial motor test run. Waiting on a new motor shaft because the previous owner cut it down and it is too short to engage the support bearing in the motor mount. Received a set of main blades and a twelve tooth pinion from Curtis today. My order from Progressive shipped today so hopefully I am completing the wiring on Friday and electronics setup this weekend. Hoping to have it ready to fly by the 23rd. Will post some pictures when done with mine, keep us posted on your progress.

Cool, Glad to see someone else building. Post some pictures and keep us informed on your progress. On my 700 I ended up going to a 11 tooth helical mod 1 pinion. With the 12 tooth my esc settings were too low a percentage to get the headspeed range I wanted. I use a Kontronik Power Jive 120 HV. With it you can go lower with out creating heat but I was close to 45 to 50 % . I changed to a 11 tooth and was able to increase the throttle curve more in my TX.