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Gas Powered Thoughts Advice for Gas Helicopter Success from Carey Shurley


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Old 06-25-2020, 01:15 PM   #1 (permalink)
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Default Build Thread - JCD Protos Gas Conversion



Overview

With the introduction of the Protos Nitro helicopter, JCD can finally produce a gas conversion where there isn’t an issue with the direction of the rotor head rotation. Take a look at what you need and how to do the very straight forward conversion!

NOTE: There are more details found in the conversion guide document, this overview does not include every detail.

Introduction

It all starts with a helicopter, for this one you will need a Protos Nitro helicopter kit


Donor Kit Required

From that kit, you’re going to need to keep these parts and assemblies


Donor Parts Required

On the other hand, these parts will not be used. If you’re converting from a damaged model, no need to replace these parts if they are damaged


Donor Parts Not Needed

Here’s what comes with the conversion kit, as always JCD kits are very complete


Conversion Parts

You will need a Zenoah RC format engine, typically we recommend one that has been balanced and modified or additional power as well as a muffler.


Engine/muffler required

You will need the same electronics as would be used in the donor model although they will be installed slightly differently and the throttle setup will be different.

Electronics required

Conversion Manual


Click on cover to see manual


Next Step
Component Assembly

Last edited by carey shurley; 06-25-2020 at 02:52 PM..
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Old 06-25-2020, 01:16 PM   #2 (permalink)
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Default Build Thread - JCD Protos Gas Conversion - Prepare Components

Component Assembly

As I always do, there are a number of components that can be assembled or converted prior to the main assembly steps. This saves time and simplifies the actual conversion

Starting with the engine mount and bearing blocks


Engine mount/bearing blocks

The engine mount uses an insert that will self align the mount onto the engine crankcase


Engine mount assembled

The drive bearings install into the drive bearing blocks as shown


Drive bearing blocks assembled

These are the parts needed to prepare the engine


Engine preparation parts

The engine mount installs onto the nose of the engine, the insert will align onto the nose of the crankcase


Install engine mount

The engine will likely include a clutch and base, install the base onto the crankshaft as shown


Install clutch base

These are the parts needed to install the clutch, some are from the clutch kit and some are included in the conversion


Clutch parts

Here you can see the clutch installed


Clutch installed

The kit includes a deflector to better direct hot air out of the canopy. It installs as shown


Air deflector

The carburetor throttle arm will need to be oriented as shown, use the control ball from the donor kit


Throttle arm

Here you can see the completed engine ready for installation


Engine completed

These are the parts needed to assemble the main drive


Main drive parts

The clutch bell will insert through the lower bearing block as shown, followed by a spacer and then by the drive gear


Lower clutch stack

The drive gear will be affixed using a set screw which connects with the flat on the clutch bell shaft. The remaining spacer sits on top of the gear


Install gear/spacer

The upper clutch block installs as shown, note the orientation of the bearing. Tighten the M15 nut onto the top of the clutch bell shaft to secure the bearing blocks


Install upper clutch block

The start shaft installs through the clutch bell shaft using the included flange bearings


Install start shaft

Install the start adapter on the top of the start shaft, the set screw will align with a flat on the shaft


Main drive completed

You will reuse the fuel tank from the donor model and make some modifications


Fuel tank parts

You will need to add a fitting for the carburetor overflow line and for a fuel fill location. The exact location isn’t important as long as it is on the right outside of the tank


Overflow/fill location

The kit includes an o-ring to help seal the overflow fitting


Overflow/fill fitting

The overflow fitting will install using the included hardware


Overflow/fill installed

These are the parts used for the fuel feed line


Fuel feed parts

It will require a slightly different process for installation


Installing fuel feed

Once the fuel feed is installed, the tank is ready for installation


Completed tank

As a final component, select the new front frame support and install the front frame support cross member from the donor model. Note the orientation of the parts


Front frame support

Next Step
Chassis Conversion
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Old 06-25-2020, 01:17 PM   #3 (permalink)
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Default Build Thread - JCD Protos Gas Conversion - Chassis Conversion

Chassis Conversion

This is the main conversion step, it combines most of the original donor parts with the main conversion parts

Because of the size of the engine, a new set of frames are required, these are the additional parts needed for that


Conversion frame parts

The main drive will install in exactly the same way as the original motor drive mount on the front of the frame skeleton


Main drive installed

Assemble all of the frame components onto one of the side frames, the right side is recommended


Frame side – inner view

Here you can see all of the mount bolts for the frame side


Frame side – outer view

Combine the two frames which will capture the main drive


Combine frames

The previously prepared engine will install in this orientation


Engine orientation

Install the engine as shown using the provided M3 x 8mm bolts. See the conversion guide for proper alignment steps


Install engine

Once assembled the frame should look like this from the right side


Frame assembled – right view

And like this from the left side


Frame assembled – Left view

To complete the main chassis, you will need these parts from the conversion


Lower frame plate parts

Install the landing gear mount, the rear mount uses parts from the conversion


Install landing gear mounts

Install the original landing gear as shown


Install landing gear

Install the lower engine plate, refer to the conversion guide for details


Engine plate installed

Slide the fuel tank into its original location


Install fuel tank

Using the included fuel vent spool, assemble it over the fuel tank retainer. Refer to the conversion guide for details


Configure fuel vent

When completed, the fuel tank vent/spool will look like this.


Fuel vent assembled

The tank retainer installs in the same as on the donor model. The tank vent spool will be towards the rear of the model


Fuel vent installed

Attach the short end of the fuel tank vent to the vent fitting on the tank


Tank vent attached

Next Step
Install Electronics
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Old 06-25-2020, 01:18 PM   #4 (permalink)
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Default Build Thread - JCD Protos Gas Conversion - Install Electronics

Install Electronics

For the most part, the electronics will be installed in the same way as originally done with a couple of exceptions. There are many ways to install electronics and route wiring, the following is just an example

Here you can see the electronics from a left side view


Electronics installed – left view

And also from a right side view


Electronics installed – right view

Now you can install the original front battery plate


Install battery plate

Use the provided Velcro to secure the battery


Prepare battery

And install the battery in its original position


Install battery

The T/R servo now installs in the back of the model. These are the parts needed to properly center it. The four spacers fit between the servo and the frame. Use the original plastic servo nuts to secure the servo into place


T/R servo parts

Looking inside the frame you can see the proper orientation for the servo


T/R servo installed – inner view

And from outside the frame you can see a suggested routing for the servo wiring


T/R servo installed – outer view

The conversion includes a switch mount, you can use this if you want. Depending on the size of your switch it can mount in the open throttle or t/r frame opening


Optional switch mount

Next Step
Complete the conversion
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Old 06-25-2020, 01:18 PM   #5 (permalink)
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Default Build Thread - JCD Protos Gas Conversion - Model Completion

Complete the conversion

There are a few steps left to complete the conversion which will be covered here

Plumb the fuel tank as shown, refer to the conversion guide for more details


Fuel tank plumbed

Secure the fuel lines so that they are moving around


Secure fuel lines

Install the main gear, autorotation pulley, main shaft and rotor head exactly as done in the original donor model.


Main gear/shaft/head installed

Use the original T/R pushrod to make up a throttle control rod. Also note the position of the ball on the throttle servo arm. Refer to the conversion guide for more details on this


Throttle Rod dimensions

Throttle control rod installed


Throttle rod installed

Make up the T/R pushrod. Its going to need to be shorter than the original due to the new t/r servo position. Refer to the conversion guide for more details


Build t/r pushrod

The kit includes a sleeve to fit over the t/r pushrod.


Included Teflon sleeve

This will install over the pushrod and be shrunk into place with a heat gun. It should fit at the same location as the t/r pushrod support and will dampen the vibration/noise that it produces


Sleeve installed

Finally install the T/R pushrod as shown


T/R pushrod installed

Your engine must have an air filter. If it hasn’t yet been installed, do it now


Install air filter

You will also need a muffler, you can install it now


Install muffler

The conversion includes optional decals that you can install


Optional decals

This is one possible location for the decals


Optional decal installation

This completes the conversion. You can configure your electronics as you normally would. Refer to the conversion guide for a suggested throttle curve

Next Step
Conversion Summary

Last edited by carey shurley; 06-25-2020 at 01:46 PM..
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Old 06-25-2020, 01:20 PM   #6 (permalink)
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Default Build Thread - JCD Protos Gas Conversion - Summary

Summary

The model as shown here weighs 11lbs - 14oz

The servos, battery or blades are not optimized for the lightest available, they are the parts I normally use in builds.















Last edited by carey shurley; 06-25-2020 at 05:29 PM..
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Old 06-25-2020, 09:07 PM   #7 (permalink)
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Love it! Can’t wait to try one, my Protos nitro is great, this will be a great addition.

Any provisions for a generator mount?
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Old 06-25-2020, 09:26 PM   #8 (permalink)
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not currently, maybe later
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Old 06-27-2020, 04:44 PM   #9 (permalink)
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Hi Carey,

Can the Protos electric be used as a donor?

Thanks.
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Old 06-27-2020, 05:51 PM   #10 (permalink)
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not practical, there are too many differences
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Old 06-28-2020, 02:05 PM   #11 (permalink)
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Thanks for the response Carey.
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Old 06-28-2020, 09:45 PM   #12 (permalink)
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Looks great. When will the conversions be available?
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Old 06-29-2020, 06:06 AM   #13 (permalink)
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will have some during July
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Old 07-09-2020, 07:31 AM   #14 (permalink)
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Default Protos conversion

Mr. Shurley, I will get one when it is available
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Old 07-20-2020, 08:56 PM   #15 (permalink)
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I put a few in the store today
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Old 08-30-2020, 11:18 AM   #16 (permalink)
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Carey,

Any problems with the Gorilla Gear spreading out?

Thanks,
John
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Old 08-30-2020, 12:21 PM   #17 (permalink)
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Hey John, there hasn't been that I can see. On the prototype, they haven't really changed and it as a nice ground clearance
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