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Old 01-04-2010, 05:22 PM   #1 (permalink)
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Cool Kustom's Bergen Intrepid Gasser Build

I have gotten a few pm's about doing a build thread for this bird. I'm not a heli expert of any sorts ,But I can make them cool looking. If you have seen my wraps on these helis. I think I will take this a step further so I can break it down, so you can see how I make the custom parts first hand. I'm sure most of you have seen the frames I made for mine. I have only finished the lower set because I'm thinking I would take pics on how I did this in case I decide to make more for sale for other Bergen owners. So if you like, I can take you threw all the steps so you can see first hand how I do them.

Now this will not be a overnight post. so I can give you the best information so I may be able to represent this company in the best way. What I would start out with is how i plan on building this machine in my vision and tell you my plans. I will do my best to keep it on track.


My Concept

When you think of Bergen's helicopters what comes to mind for me atleast is American pride, so I figure I will stick with the simple red,white,and blue cause those color don't run. I will being doing every part in this color idea from the frames to the servos no detail will be left out.. I wish I could get into for what i have for a canopy but to tell the truth I have started many concepts and can't decide on one , so i think i will have more canos then my wife has shoes..

Enough of my ramblings let get started I will spare you the first pic of the box of parts I'm sure everyone has seen this before,but I will say you need a shop vac and a big bag for the packing .. in my case i put them in a bag and my kids use it like a bean bag thanks Chris that they liked more then what santa brought them .

The first thing i will show is how I made my fames so instead of making one huge post I will make a lot of smaller ones. Thanks for reading

Kustom
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Old 01-04-2010, 06:27 PM   #2 (permalink)
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Subscribed.

I am looking forward to your build. I think it will be one great American Helicopter.
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Old 01-04-2010, 06:33 PM   #3 (permalink)
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You've got my attention
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Old 01-04-2010, 06:48 PM   #4 (permalink)
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Default My frames

Ok, as I said before, I will break it all down to show as much as I can with out using video..

The first thing I had to address was how to get the frames in the computer to the right scale. I tried many ways but they were taking up way too much time so I opted for option B; I went to a copy place that has those huge flat bed scanners and got them to pop them on a CD for me. OOO $10 no big deal that's cheaper than what I charge my customers for my regular work. This is what I ended up with:



As you can see, it's not to scale here for certain reasons but you can see what I started with. The next step was for me to bring it into my editing software, clean them up and set them up for making up a template:



As you can see on the right in the same photo you can see what the finished product looks like stacked. If you would like to learn how I did this PM me because doing these steps is very time consuming. I don't want to stray too far from the point. In my next update I will show how I put them on the frames.

UPDATE

This is how we going to install them. As you can see in the pic below, it starts as a simple print - it's not pre-cut due to the fact of speed. It's just as easy to trace it out with a razor knife.



You can see it in the picture due to the size before I start cutting this out, I'm looking for an outline I made and making a bunch of extra cuts so i can remove the extra in large pieces.





All finished! 10 mins time and this is what you end up with. Now on to the FUN part!

Unless you think you're special for some reason, ALWAYS clean your parts I use an automotive prep for painting . I also like to use a primer for under my graphics. It's not a must-do thing and I will show you why later.

The primer I use is a 3M product called Primer 94 that's mainly used by graphic companies to make things stay in tight joints such as wraps. (I use it on the wraps I make for people). If you happen to get a hold of this and decide to try it out, be warned that it will act like a super glue and 9 times out of 10 you will damage your print if not careful . LESS IS MORE



The best way to get this right is to start in the center and work out towards the sides. I just let it lay on the part, - NOT pressing down or it will stick - making sure all my sides are lining up. I mentioned earlier about an outline I put on it; when you trim up the frames you will trim that line off during trimming so it's no biggy. Please take note that I did not cot out any of the white parts in the center or the other. The main reason for that is so it will stay straight and not make it harder to install.



Now that it's in place, to get it stuck down I just use a squeegee or a credit card - whatever will work.



Now that it's all down good and flat it's time to make sure it will stay without peeling up or shrinking. This material can be heated up to make it stick better or make it stretch. In this case I'm using a heat gun on LOW to heat it up and make the glue and primer one. If you're unsure about this I'd say you can use a hair dryer to get the same effect. If you get too close you will melt this stuff fast. I'm holding the heat gun away at least a foot off the material and working it back and forth. You know you have it when you notice that white area of the print that not supported on the back side starts to flex by tightenng on the surface.



One thing you can do when warm is go over it again with a squeegee just to make sure it's down good. Here you go just my little way of making something special to stand out from the pack .



I hope you enjoyed reading this as much as I did writing this .

In my next post I will be talking about the lower gear and the lower frame build. I'm not going into a step by step just little tips that might save you time .

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Last edited by Skiddz; 01-07-2010 at 11:48 PM.. Reason: Cleaned up at Kustom's request
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Old 01-06-2010, 07:58 PM   #5 (permalink)
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edited above for a update
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Old 01-06-2010, 08:43 PM   #6 (permalink)
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So is it done yet??
I really like the way it looks so far!!
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Old 01-06-2010, 08:50 PM   #7 (permalink)
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Man! Thats going to look too good to put a canopy on!
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Old 01-06-2010, 09:06 PM   #8 (permalink)
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thanks for the kind words
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Old 01-07-2010, 05:15 PM   #9 (permalink)
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Looking good Gary. You're already quicker than bill. You've taken the pieces out of the box within two weeks of getting the heli.
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Old 01-07-2010, 09:50 PM   #10 (permalink)
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Heartless...
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Old 01-08-2010, 06:40 PM   #11 (permalink)
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Thanks for the Pepsi Gary........
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Old 01-08-2010, 07:57 PM   #12 (permalink)
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Opps... shamless product plug
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Old 01-08-2010, 08:08 PM   #13 (permalink)
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I'm subscribing, this will be a special build. Thanks for sharing Kustom!
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Old 01-08-2010, 09:38 PM   #14 (permalink)
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Quote:
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Opps... shamless product plug

Post #4, pic #4.... I figured since you had some Pepsi I would grab one out of the fridge.

Nice build thread.
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Old 01-08-2010, 10:18 PM   #15 (permalink)
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I just have to ask. Why are there white areas where the frame openings are. Couldn't one just complete the flag pattern and then trim out the openings and edges later?
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Old 01-08-2010, 11:32 PM   #16 (permalink)
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Joe,
Why yes I could have but it you look at the pics more carefuly you will notice there is a patern as in the wavy flag that has to match up with the lowers when stacked . idesign stuff to make it simple besides the big hole in the center is the starting point if it was not there you would not know if the tops and the bottoms would line up right . it's not that i'm tryign to save time but if i sent you to big flags and said here ya go they will match but it's on you to make it work. i won't sell or make anything that a normal person could not do. I talked with Chris about it as well today. if i make them for the Bergen owners i would want o make it a easy up grade.
p.s. another reason for the holes is for me to make the patches that i will be wraping my servos with .. I hope this made sence

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I just have to ask. Why are there white areas where the frame openings are. Couldn't one just complete the flag pattern and then trim out the openings and edges later?
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Old 01-08-2010, 11:36 PM   #17 (permalink)
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Now is it done??
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Old 01-08-2010, 11:59 PM   #18 (permalink)
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This is going to be interesting. I can understand aligning the match. I will probably understand more as the project progresses. I found a previous thread with a canopy you did. Really wish I would have seen that one in person. Nice talent you possess.
http://i153.photobucket.com/albums/s...s/100_2341.jpg
Thanks for sharing your efforts. Waiting patiently.
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Old 01-09-2010, 12:02 AM   #19 (permalink)
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In my albums is another canopy Gary did also. The one in the Beam album.
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Old 01-09-2010, 12:21 AM   #20 (permalink)
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THanks Joe
That was The First Bergen cano I did. Chris was one of the first people to give me a shot to show what i can do, But yes you will notice when i get futher along in the build why i do things a certin way. I'm working on some stuff on the lowers and the landing gear I missed with the pic's but i can still add them and point out the tips
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