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The Days with the MS Hornet 1 and MS Hornet 2

HANDMADE FLYBARLESS ROTOR HEAD

HANDMADE “MFS” MOVING FLYBAR SYSTEM-  ROTOR HEAD

Making a New Tail Gear Box

New Frames for Lay Down Servos with 120 CCPM

ORIGINAL MS HORNET


11-13-2002

HANDMADE FLYBARLESS ROTOR HEAD


I have started building a new rotor head with aluminum blade grips. I had to write much of the code and since my 4th axis is still unavailable I had the machine stop at certain points were I would rotate the part as needed (I was the 4th axis). Here is a picture of the grip after it was turned down and milled on all 4 sides.

11-24-02


Back on the lathe. The rotor blade fits perfectly! I just need to bore out the hole for a 6 mm bearings and then cut it off. Pretty Neat!


Here is the finished head. Right now I have the grips mounted on an ECO's tailrotor hub. Just need to add ball links, perfect the tip weights (around 6-7 grams) and give her another try.


My design is more or less a copy of the work from others. Thanks guys for putting in so much R&D to get this heli flybarless. 11-24-02


UPDATE:


The heli didn't work. It's very difficult to keep control. I don't think I have the weights in the blades right. I have read that 1 US nickel weights about 5 grams. That is about how much weight you want. Lets try something else. Next?

HANDMADE “MFS” MOVING FLYBAR SYSTEM-  ROTOR HEAD


Moving Flybar System (MFS) rotor head. Here you can see the main head block being drilled. I turned it and then put it on the mill cutting it every 90 degrees!

11-28-02


Here is the complete head, well sort of. I just need to made an anti-rotation for the swashplate and its time to try her out. You can see the flybar and rotor blade almost have a 1:1 ratio! Hope it works!

11-29-02


Is is another picture. You can see how the flybar moves up and down in that groove. A 6 mm bearing rides in there to help to smooth the motion.


The entire flybar assembly moves up and down via the "L" shaped flybar pieces. Since the main grips are attached to the flybar carrier they move too (all yellow arrows) giving pitch.


For cyclic, the "L" pieces move again but this time one up and the other down. Paddles deflect, flybar assembly deflects (like a normal heli) and the main blade grips move since they are attached to the deflected flybar carrier. This time however, 1 moves up the other down. Neat!


My pinion gears stripped again. This time I used a metal gear from an older Futaba servo. The top part of the "2 level gear" is a great fit. Drill out the hole using a 1.93mm drill bit.


I am sure I will regret this as something has to fail. This means the more $$ part probably will :):)


Here is the head on the heli! Looks promising!  

12-03-02


NEW FLYBAR CONTROL PARTS!


The flybar assembly broke and I had to remake it. This time I made it right. Here is a "blow up" picture of the head with parts, most of them, fully one piece! I also made the anti-rotation link this time. Everything fits, time to test her out!

12-03-02


HORNET LIFTS!


The hornet flew and was Very Stable! Almost No trim changes needed. If I could just keep the tail working it would be great. I had very little cyclic and the poor heli ran into the wall chipping one of the main blades. I put in a new shaft and tightened a few things but the tail just gave up and the main gear stripped. However, the collective was very smooth.


I found the hole I drilled to be larger then the existing one, about .04 mm too big! Yep, a tiny number but it shows up in shakes.

12-04-02


I have ordered new parts with the conical tail gear setup. Once I burn these out I will start looking into a belt drive system.