START HERE |
|
Register | FAQ | PM | Events | Groups | Blogs | Calendar | Mark Forums Read |
Unregistered
|
Synergy Model Helicopters Synergy Model Helicopters Support |
|
LinkBack | Thread Tools | Display Modes |
09-21-2011, 09:38 AM | #1 (permalink) |
Registered Users
|
Synergy E7 Build Thread
I started my E7 build last night, and I was instantly surprised how simple the build was. Everything is fitting perfectly and so far I have found only one issue.
The Box, isn't it pretty: Bottom Plate and ESC mount Main Gear and Main Shaft: The instructions have you build the main gear, autorotation hub first so when you install the main bearing blocks you can properly align. Delrin Main Gear - Slant cut should be smooth and quiet Delrin Belt Pulley with CNC Metal alignment guides to keep the belt in place Main Gear and Autorotation assembly built. One note, this is the one place I have found an issue so far. I had to install the autorotation hub upside down relative to the instructions because the one way bearing was pressed into the hub the wrong way. From what I can tell by sight and measuring with my Calipers, the autohub is symectrical once installed and everything lined up perfectly. Possibly a miss print, or possibly an assembly issue on my kit. But this was an easier fix for me since I don't have access to a bearing press to reverse the bearing. Second view of Complete Main Gear and Autorotation hub Beginning the frame assembly. Starting with main bearing blocks. There are 3 bearing blocks on this bird. The bottom block has slotted mounting holes so that you can align the shaft before securing the block. Very clean install, no surprises here. Second view, bearing blocks installed on one side of the frame. Installing the belt idler assembly. The instructions suggest installing the tail control servo now prior to closing the frame. Once the rear frame braces and optional rear gyro mounting location plates are in, the access to the servo mount is limited. I am not sure if I will use this gyro plate, but it ads support to the rear frame none-the-less. Basic Frame Complete.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
Sponsored Links | |||
Advertisement |
|
09-21-2011, 09:39 AM | #2 (permalink) |
Registered Users
Thread Starter
|
Up next:
Servo install and Anti-Rotation bracket Anti Rotation Bracket. This kit uses a CF anti rotation bracket that also serves as a cross brace for the main bearing blocks. The servos mount directly to the main bearing blocks on this kit. I decided to use JR DS8717 High Speed Cyclic Servos. The kit also comes with CF servo arms designed to mount to a standard servo wheel. My servos didn't come with a wheel that would line up with these cool looking arms. The instructions give you the ball distance measurement of 20mm should you need to use your own servo arms. Here are the mounting locations of the Cyclic servos: Pitch Servo: Aileron Servo: Elevator Servo:
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-21-2011, 09:39 AM | #3 (permalink) |
Registered Users
Thread Starter
|
OK the next step in the manual is the landing skids. I was particularly impressed here. Unlike most kits I have built that use a set screw to hold the skid post to the tube, the E7 kit came with a specialized nut that slides down into the rod and a bolt goes through the strut and into the nut locking the skid pipe in place. I didn't think to take a picture of the nut, I am sorry but this was surprisingly easy to get lined up. A well thought out idea here.
Next step is the tail boom clamp assembly. This is a very simple setup with two clamps and a very rigid piece of 2mm CF to brace it. There are two holes in the frame sides to get a hex driver in to tightened the clamps once you mount the assembly. All in all, made for a very clean tail boom install. Tail Boom Clamp mounted to the heli frame. The Motor Mount and Pinion Bearing block are up next. This kit uses a 30mm motor mount bolt spacing and is made from a very solid nearly 1/2 inch thick piece of CNC Milled Alluminum. The Pinion Bearing Block has a user replaceable bearing that I would assume could be changed to accomodate 5mm shafts. The kit came setup for 6mm motor shafts which matches up to my Tornado motor perfectly. Motor mounted and a 14T pinion installed. It took some work trial fitting the pinion to get the spacing on the shaft just right. Hacker has milled one entire side of the shaft with a flat spot so I was able to get the pinion perfect and still tighten the set screw against a square surface. Here is a fairly good angle on the motor and pinion bearing block installed. I haven't set the gear mesh yet on this picture but you can see how much room there is in this kit. I could have easily stuffed a much bigger motor into this frame with no mods at all. A second view of the motor mounted. This time the mesh is set and the motor is tightened up and loctite applied. The directions have you mount the ESC plate at this point. This is also made from very rigid CF and is large enough to accommodate even the largest ESCs. My CC ICE2 120HV fits perfectly. I wouldn't normally mount the ESC just yet, but so far the instructions have had a reason for mounting the electronics in this order so I followed suit. ESC mounted. A view of the motor wires tied up cleanly below to stay clear of the battery compartment. Ok it is finally time to start building the tail boom and tail rotor assembly. The kit comes with everything you need to build the bird as an E6 or E7 so you have to do a little work here. While they provide two sets of control rod, tail boom supports, belts, and of course the booms themselves, you have to reuse the hardware. Mine came with the hardware setup on the E6 boom supplies, so I first had to get everything laid out for my E7 build. A little medium CA on the tail boom supports to hold the fittings on and these are ready. Notice the brass sleeve in the one end. I was impressed with this. Most kits just have a bolt going through the plastic and when you tighten it down, you deform the plastic rod end. This sleeve allows the bolt to tighten up against a rigid surface and prevents the rod end from deforming. Very nice touch. The Boom installed. Another spot of great engineering. It's the little things on this kit that continue to impress. Where the support rod ends bolt to the frame, they have notched out the CF so that the rod end can set flat against the frame side, again allowing a perfect fit without deforming any plastic. Nice touch guys. Up next is the tail rotor and main rotor.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion Last edited by Chris Sexton; 09-22-2011 at 08:01 AM.. |
09-21-2011, 09:40 AM | #4 (permalink) |
Registered Users
Thread Starter
|
Ok the tail came assembled but I of course pulled it apart to make sure everything was loctited and fits perfectly. Nothing out of the norm here.
I was impressed again with the tail rotor. They use (2) radial bearings AND a thrust bearing in EACH blade grip. The Tail Case is made from CF and alluminum. I was worried about the stability of building this out of CF, but this thing is so beefy, I would wager is it as strong as any of the alluminum cases on my other helis. Tail rotor greased up and reassembled. Ready for install. Lining up the belt on the idler pulley and rear drive gear. This was really easy with one side of the case off but still loosely bolted to the tail boom. Tail case complete and ready for the rotor. Tail is complete, ready to set the belt tension. I have not built a lot of larger belt driven helis so this might be standard, but I liked the idea of adjusting belt tension at the tail case. I thought it was a lot easier to handle and get the tension just right. It did take a bit of work to get the tail rotor rotated into the correct orientation relative tot he main shaft. The only thing I would have liked to see here would be a way to pin the tail case. While the two clamp design applies plenty of clamping force, there is no "pin" to help prevent the tail from rotating should the clamps loosen up over time. Nothing a little pre-flight check can't catch. Moving on to the Main Rotor Assembly. Again this came mostly assembled but I will pull it apart and check everything. Closer view of the massive FBL head. This thing is as beefy as everything else. Polished doesn't hurt it either. Ok, swash plate fully assembled and loctite applied to all of the balls. The E6/E7 uses 3 radial bearings for the anti-rotation brace. This is yet another example of good engineering. By using bearings you are helping to eliminate drag on the swash when a normal post might bind under pressure. NOTE: I just noticed my picture of the swash is BEFORE I tightened the balls. That is why they look loose, because they are Again it was getting late. Head re-assembled and ready to go on the bird. I was getting tired and didn't think to shoot photos of the grips apart, but as you would expect, 2 radial bearings and a massive thrust bearing for each side. The dampeners provided are very stiff so this thing should love hard 3D! I decided it was getting too late, about 2am local at this point so I stopped here. I did "dry" fit the head and swash without linkage rods to see the actual height of the heli head. Air frame COMPLETE! I couldn't resist putting the canopy on and seeing my beauty before calling it a night. All in all, I am extremely happy with the build. Quality of the parts are top notch. I did end up having an issue with the threaded rod provided for the swash to servo linkage. I had an unopened pack of 600EFL PRO Linkage and the Synergy rod ends threaded right on. Tomorrow we will tackle the final head setup and electronics programming. I am planning to maiden this bird at the 4th Annual Buckeye Fun Fly in Delaware Ohio on Saturday. I will try and con my buddy into shooting some video of the maiden.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion Last edited by Chris Sexton; 09-22-2011 at 08:46 AM.. |
09-21-2011, 09:40 AM | #5 (permalink) |
Registered Users
Thread Starter
|
Time for my least favorite part. Soldering the connectors on my BEC and building my series connector.
I decided to build mine with the 3GX system I had already laying around. I have flown most of the current FBL systems, with update 1.1, the 3GX holds the tail nicely and is very compact. I might eventually upgrade this to a BeastX but my wife might shoot me if I drop another $200 on this bird right now. I was not able to find any JR spined wheels that would line up with the fancy CF servo arms provided. So I picked up a set of Du-Pro arms that have a 20mm spacing. I started with all the linkage at the lengths provided by the manual. I did have to adjust the pitch links a bit, but not much. The book was fairly close. Servo arms installed. Swash installed and ready to start running my electrical wires. Wire runs on this heli were fairly straight forward. I ran the ESC Throttle line up one side of the frame and the remote sat lead up the other side. The cyclic servos were a bit tough. I thought seriously about shortening the leads to take up some of the slack, but I am not the best at soldering small wires like that. Ultimately I just did my best to keep everything clean and used the long side frame in the back to help me "loom" the wires up. Not my best wiring job, but I think it came out very clean in the end. I decided to mount the RX on the side of the frame as to not crowd the Gyro. I decided to mount the BEC under the rudder servo on the optional rear gyro mount. This allowed me to keep it off the side of the frame and ultimately makes the heli so clean with the canopy on. Electronic install complete. All I have to do now is level the swash and setup the head. And the rotor head is installed, pitch ranges set and verified. This bird is almost ready to fly! I still have to work out my series harness. I have one from my 600 EFL Pro that works, but the leads are way too long. I will probably maiden it with this cable and once I commit to a long term battery setup I will build a custom harness for it. Well, she is finished! I know I have said it, but I am going to say it again, this has been one of my favorite builds. Everything fit together nicely, and aside from a couple very minor issues, the kit was complete. I hope this thread helps anyone who is thinking about an E6 or E7. Thanks for following along. I am going to throw in a bunch of general shots I took last night. I can't wait to get this puppy in the air! Complete and ready to fly. Thanks again guys! See you in air sometime.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion Last edited by Chris Sexton; 09-23-2011 at 08:53 AM.. |
09-21-2011, 09:49 AM | #6 (permalink) |
Registered Users
Thread Starter
|
This is as far as I got on the first night. Tonight I plan to finish up the servo install, maybe take a couple minutes and plan my servo wire paths before I move on to the tail.
Hopefully this time tomorrow I will have the tail assembly mounted and ready to move on to the head. Stay tuned.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-21-2011, 10:53 AM | #7 (permalink) |
Registered Users
Join Date: Jul 2008
|
Looking good
__________________
Team Synergy Last edited by bmw576; 09-21-2011 at 02:18 PM.. |
09-21-2011, 10:56 AM | #8 (permalink) |
Registered Users
Join Date: Jul 2008
|
What FBS are you going to be running? Let me know how the carbon fiber arms mounts up the the JR servo horns.
__________________
Team Synergy Last edited by bmw576; 09-21-2011 at 02:19 PM.. |
09-21-2011, 11:21 AM | #9 (permalink) |
Registered Users
Thread Starter
|
I am waffling between the Align 3GX system since i have one laying around or buying another BeastX system. I am familiar with both and enjoy flying both. The maiden will probably happen with the 3GX just because it is handy.
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-21-2011, 06:32 PM | #10 (permalink) |
Registered Users
Join Date: May 2004
Location: Northern Vermont
|
Good pics and notes. Keep them coming.
|
09-21-2011, 09:42 PM | #11 (permalink) |
Registered Users
Thread Starter
|
Well it looks like my kit is missing a parts bag. I am missing the tail control rod guides and the links for the end. I thought I was missing the threaded rod but I found that in the head bag.
Another issue I have come across. The quality of the threaded rod provided for the linkage is poor. All of my swash plate rod was burred up so bad I had to use some trex600 threaded rod i already had. Not sure what I can do about the tail control rod guide sleeves. The boom mounted push rod guides are too loose and there will be slop on the rod if i don't use the guides. I guess I will call aero-model tomorrow and see what they say. Had anyone else had this problem? Sent from my iPhone using Tapatalk
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-21-2011, 10:12 PM | #12 (permalink) |
Registered Users
Join Date: Apr 2004
|
Hello,
quality of the threaded rod - we are looking into this right now. tail control rod guide sleeves - if they were missing I will send you some. Send me an email at matthew_botos@yahoo.com and I will get you all squared away. Thanks, Matt |
09-22-2011, 12:14 AM | #13 (permalink) |
Registered Users
Thread Starter
|
Wow certainly wasn't expecting the heli designer to be reading my thread!
I was able to take a file and smooth out the burr on the ends of the swash to grips rods. I used a set of Trex 600 efl pro rods for the servo linkage. I think that they simply didn't cut the rods cleanly after cutting the threads. Simple assembly mistake. It might even be a one off. I am that lucky! I will shoot you an email, I have looked through everything I am missing the tail rod control sleeves. All in all, she is a beautiful bird. I am glad everything I loved about it at IRCHA stayed in tact for the production version. Sent from my iPhone using Tapatalk
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-22-2011, 06:15 AM | #14 (permalink) |
Registered Users
Join Date: Apr 2011
Location: US
|
Definitely a cool thing to see active support like this!
The pictures look great! The kit looks well engineered! QC in manufacturing is always a fun thing to get worked out. Hopefully the production runs will only improve, and if the product is worth having, these are just a few bumps in the road! My gut reaction is that it looks nicer than a Mikado and more rugged than a Henseleit, which puts it in good company.
__________________
Mark Dusty Shelf queens: TDR2, TDR, Protos Max, Logo 550SX, Protos 500, Jeti DS-16, etc.... |
09-22-2011, 06:44 AM | #15 (permalink) |
Registered Users
Join Date: Apr 2008
|
I want one too great Heli
__________________
AP Logo600SX:Pyro 700-52 -Vbar-3x610 -bls251-Vbar GOv-Hw PL120HV-Thundepower Logo6003dXera 560 - VbarGov - 3x8717 - Bls251 - Hobbywing PL 120Hv-Thunderpower Cinestar 8 Cs gimbal - HoverFlypro - Tiger motors 710-Radians-Turnigy Plush 40A |
09-22-2011, 08:10 AM | #16 (permalink) |
Registered Users
Join Date: Dec 2010
|
I'm I ever anxious to maiden mine.
|
09-22-2011, 08:29 AM | #17 (permalink) |
Registered Users
Thread Starter
|
OK Tail build and both rotors built. Thread updated.
Tonight we will finish the electronics and setup the head. Maiden will be at the 4th Annual Buckeye Fun Fly in Delaware Ohio this Saturday. Hope to see you all there!
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
09-22-2011, 01:41 PM | #18 (permalink) |
Registered Users
|
Man I love the way the Synergys look!
__________________
Lincoln #HIGHONHELIS ):> Pull Hard RCHO Flying Field, Knightdale NC |
09-22-2011, 03:22 PM | #19 (permalink) |
Registered Users
Join Date: Oct 2010
|
Looking badass, can't wait for mine - thanks for the pics!
What size are bolts on the kit? ps. Please consider including a Synergy towel in the kit or at least selling it separately - I am tired of Align towels in every build thread
__________________
TDR/VBar Logo 600SX 12s VBar MSH MINI PROTOS/CGY750 |
09-22-2011, 05:22 PM | #20 (permalink) | |
Registered Users
Thread Starter
|
Quote:
Sent from my iPhone using Tapatalk
__________________
Synergy Factory Specialist / Rail Blades / Team Scorpion |
|
Thread Tools | |
Display Modes | |
|
|