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Old 08-12-2018, 06:11 PM   #1 (permalink)
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Default 516 build

Hi and welcome to my build thread. I picked up the kit and blades from Matt at IRCHA. Thanks, Matt. This is my first Synergy. My first thought opening it up was how nice all the metal work is. Very nice.



Electronics are on order and I should have them by Friday but I couldn't wait to start building. (I already have the MKS 980 and Spektrum sat receivers from other helis.)

I also ordered red loctite and boto-lube so am waiting on those too. So, I'm skipping some parts for now and doing others out of order as you will see. Also I just used blue loctite on some screws where the manual mentions red. I've never had any screws come loose with blue. Even pinion set screws. I guess I don't put on enough flights for it to matter. However, I was out yesterday and was impatient and picked up some red loctite so I can do some things I skipped before next weekend.

my work desk:



























more pics in a minute...
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Old 08-12-2018, 06:19 PM   #2 (permalink)
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It took me forever to get the shaft to fall through like this. Hopefully it's still this square when it's all done:


DSC 0643 (0 min 3 sec)




more pics






The little skid ends were hard to install. I had to do some work with a hobby knife and then kind of bang them in (off the heli so to not shake everything )



















Looking down the boom. I just thought this photo looked cool.



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Old 08-12-2018, 06:23 PM   #3 (permalink)
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last round of pics today.

To get the swash ball reasonably free and smooth, I took it all apart and put it back together, barley screwing in the 4 bolts. I just screwed them in until they stop and no more. If I tightened at all, the ball gets resistance. I will definitely be checking on these bolts after at least the first several flights to make sure they are staying in.








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Last edited by ultrataco; 08-13-2018 at 09:18 AM..
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Old 08-13-2018, 09:09 AM   #4 (permalink)
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Awesome! I’m hoping to make my next heli purchase in September the 516, so this thread is very timely 👍🏻


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Old 08-13-2018, 06:44 PM   #5 (permalink)
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Do yourself a favor and mod it to use magnetic mounts for the canopy. While it's not as easy as with my non-Evo Protos Max V2, getting it on and off is a lot faster and easier than with the stock mounts.
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Old 08-14-2018, 03:58 AM   #6 (permalink)
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Good advice!....I have a spare set of my Protos 380 magnets already in hand


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Old 08-14-2018, 07:21 AM   #7 (permalink)
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Quote:
Originally Posted by TheBum View Post
Do yourself a favor and mod it to use magnetic mounts for the canopy. While it's not as easy as with my non-Evo Protos Max V2, getting it on and off is a lot faster and easier than with the stock mounts.
Do you have links for the parts you got from McMaster?
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Old 08-14-2018, 05:48 PM   #8 (permalink)
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Quote:
Originally Posted by TheBum View Post
Do yourself a favor and mod it to use magnetic mounts for the canopy. While it's not as easy as with my non-Evo Protos Max V2, getting it on and off is a lot faster and easier than with the stock mounts.
I have the protos 380 mag mounts on my 516, but use them on the front only. just installed the canopy portion , removed the stock front mount pin, and replaced with a bolt ( screw) and plastic bottom screw piece that comes with the "skid-clamps" the plastic cup holds the magnet center and the bolt (screw) is enough to attach the magnet too... works slick !!!
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Old 08-14-2018, 06:05 PM   #9 (permalink)
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Quote:
Originally Posted by ben_beyer View Post
Do you have links for the parts you got from McMaster?
Sleeve washers (rear only):
https://www.mcmaster.com/#97215a113/=1e5oynp

Centering washers for the sleeve washers (rear only) (they go inside the 1/4" sleeve washer holes after minimal reaming of the holes):
https://www.mcmaster.com/#93475a210/=1e5p1ma

Standoffs (rear only):
https://www.mcmaster.com/#95947a704/=1e5oza7

Screws for attaching the magnets to the canopy and frame:
https://www.mcmaster.com/#92125a130/=1e5ozql

Reinforcing spacers for canopy grommet holes:
https://www.mcmaster.com/#93657a005/=1e5p0c9

Cap nuts for canopy magnets (these will show on the outside of the canopy):
https://www.mcmaster.com/#94000a330/=1e5p0uj

Backing washers for the canopy magnets (takes some of the stress off the magnets, which are somewhat brittle) and cap nuts:
https://www.mcmaster.com/#91116a120/=1e5p2i5

The front frame magnets directly abut the frame without sleeve washers (the canopy will get hung up on the sleeve washer if used). If you need them to come out a little further, just use one of the backing washers above.

I used these magnets from K&J Magnetics:

https://www.kjmagnetics.com/proddeta...822CS-P&cat=15
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Old 08-14-2018, 06:28 PM   #10 (permalink)
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Quote:
Originally Posted by thebirdman View Post
I have the protos 380 mag mounts on my 516, but use them on the front only. just installed the canopy portion , removed the stock front mount pin, and replaced with a bolt ( screw) and plastic bottom screw piece that comes with the "skid-clamps" the plastic cup holds the magnet center and the bolt (screw) is enough to attach the magnet too... works slick !!!


Interesting, any pics?


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Old 08-14-2018, 07:55 PM   #11 (permalink)
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umm forgot my phone at work, will post some tomorrow
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Old 08-14-2018, 09:21 PM   #12 (permalink)
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not much progress today. I really need that boto-lube.

red loctited these gold shim washer things











I got the esc in the mail today. I know 120 is probably overkill (heck I have a 130 on my Max) but it was either this or the 100 v3 and I wanted a v4 for telemetry. They weigh about the same within a few grams. ...Though now that I think about it maybe the 80A would be have been ok? That's what I have on my Logo 480. Would have saved $60. Oh well.

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Old 08-14-2018, 09:26 PM   #13 (permalink)
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I love the protos mounts but I don't think I want to bother making some for the 516. Might change my mind later though.
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Old 08-14-2018, 10:33 PM   #14 (permalink)
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oh you will want to.

i resisted at first too, but caved quickly and happily after a few trips to the field.
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Old 08-14-2018, 11:13 PM   #15 (permalink)
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Especially after dealing with the front mounts a few times.

The rear mounts are less of an issue, but I find that the canopy comes together more uniformly with magnetic rear mounts vs. the peg type quick mounts.
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Old 08-15-2018, 07:42 AM   #16 (permalink)
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Quote:
Originally Posted by ultrataco View Post
I love the protos mounts but I don't think I want to bother making some for the 516. Might change my mind later though.
You will in quick order. This model is brilliant everywhere, but the one and only thing I feel that could be improved is the canopy mounting.

The canopy grommets are soft silicone rather than hard rubber and can be cut through within just a few uses. You can mitigate this by opening the holes up in the canopy a fair amount, but it's a still a little finicky and frustrating trying to locate the front pins into the holes. It feels like you are required to stretch it up front to the point of cracking the canopy.

I'm using one of the flat magnet pairs shown in the links provided from K&J magnetics on each side up front without any cups or other modifications and a straight bolt on of the Protos 380 cup magnets on the back. I can remove & install my canopy in 5-10 seconds without having to stretch it up front at all. The magnet simply slide right onto each other, and the battery will not allow the canopy to lift up front at all.

I'm also running a HW 80V4 and its working fine for my sport flying style. I did manage to shut it down once in many, many flights due to overheating while running 2700 RPM, 13* pitch and doing a series of hard collective/cyclic combined moves in the hot GA summer heat. This was never a problem until the ambient temps started getting near 90F. I lowered my max RPM to 2500 and max pitch to 12* and installed a fan. The ESC is running cool now in the logs and the external case is only 110F after a 5-6 minute flight, but of course YMMV depending on how and where you fly.

Synergy magnetic canopy (0 min 10 sec)
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Old 08-15-2018, 08:04 AM   #17 (permalink)
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Same here with both canopies; Protos cups on back, K&J flats on front. Separate the rear, lift the rear up a bit, all comes loose. 4-9 seconds here, Tony Dan
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Old 08-15-2018, 08:12 AM   #18 (permalink)
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I think the 120amp ESC was a good idea. I use the Scorpion 120-06 on mine. I wouldn’t go smaller.

Magnetic mounts for the canopy are the way to go.
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Old 08-15-2018, 08:21 AM   #19 (permalink)
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Using talon 90, but telemetry data shows a 60 would be just fine. Lower kv motor from hacker and "not insanely ballistic" headspeeds ESC needs always depend on your individual setup and headspeeds
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Old 08-15-2018, 10:48 AM   #20 (permalink)
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Quote:
Originally Posted by dogbreath View Post
Same here with both canopies; Protos cups on back, K&J flats on front. Separate the rear, lift the rear up a bit, all comes loose. 4-9 seconds here, Tony Dan
I already had the sleeve washers from when I put mag mounts on my DT machines, so I just decided to use a home-cooked solution instead of the Protos mounts. Either one will work well.
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