Entstehungsgeschichte Helikopter CH-7, HB-YNB

Update 18th April 2016: The helicopter HB-YNB has now 311 total hours (flying-, not blockhours!) This means about 100  hours during the last 12 month.

First contact with the Helicopter  (CH-7 Heli-Sport)

What you see is the new model Charlie with new cowling and the gear fairings for better and faster cruise performance. Together with Ligi Barbero I could do a one hour test flight. Ligi is a very good flight instructor and he had no fear to let me try everything I wanted to find out, including a simulated auto-rotation. After this weekend I was completely convinced, that this is the helicopter I’m going to build Modell Charlie, see the carbon fairings and new shaped engine cowling

Preparation for 1st take-off

Is there room enough for my legs?

July 2006: I decided to pick up the kit in Torino myself, not only because the shipment and the cage would be very expensive, but also because I thought, that it would be a nice trip to Torino. We departed on a Sunday afternoon and arrived in a nice small hotel about 8pm. After a delicious Italian meal and a very nice wine we slept very well and were ready the next morning at the Strada Trafero del pino, 102-10132 Torino as agreed, 9am. After a very warm welcome by Claudio Barbero we started to pack Armin’s Ford-Transit. Our aim was to show up at customs at Ponte Tresa, a small border crossing-point near the city of Lugano, not later than 3pm. We were informed that the customs close their offices at 6pm. To be there rather early was a good decision. It turned out that the Italian custom officer was not happy with my papers. He wanted to be sure that we were not going to export critical military material. Thank God, Claudio Barbero was still in his office and could provide the custom office with the required declaration. The swiss customs-officer then was very kind, he even worked overtime to let us pass, a few days later I promptly received all the papers I will need later on when I will do the registration of the helicopter at FOCA. Late in the evening we arrived in Furna /Switzerland and quickly unpacked the Ford and stowed everything in the workshop.

Welding the fuselage, Claudio Barbero, right, fuselage is under pressure to make sure there’s no leak

Armin Egli, a good friend was so kind as to help me picking up the 1st Kit with his car.

Happy but tired we arrived late at night in Furna

At home, I firstly had to find out what was / is in all the boxes! First kit, lot 1, includes basically all material without the main gearbox, tail rotor, rotor blades and engine. Everything is nicely packed and numbered, so the material is easy to find later on when assembling starts following the construction manual. The fuselage comes with a primer on it; one has just to select his favourite colour and can apply it. I decided to use the new bright and shiny orange Ford is using for their new car. From my previous project I knew a good paint shop in Pfaeffikon, Carrosserie Sandtner AG, Spenglerei + Spritzwerk, www.sandtner.ch. I prepared everything I thought should be painted and got it ready to be picked up. Horst Sandtner was so kind and lent me his mazda to carry all the stuff to bring it to his paint shop and back to my workshop.

…still an almost empty workshop…..

Content checked and ready to be used!

First lot ready to paint.

First assembly steps(26.08.2006)
After finding out how the construction manual works, I could start with the first steps. (CD, HTML based, instead of the manual, the lap-top is required in the workshop.) I quickly found out, that the bolts used to mount the skids to the gear were too short, 1-3 threads were not visible after tightening the nut. I know that this will not be accepted during the EAS (http://www.experimental.ch/) / FOCA (http://www.aviation.admin.ch/) inspection later on. Consequently I had to order a „mechanic’s kit, bolts and nuts“ from Aircraft Spruce.

Back from Sandtner, a very nice job!

First step is to put the gear on to the skids

…and after a while it already looks like a helicopter!

Pedals(09.09.2006)
The installation of the pedals and the corresponding rod until up to where the tail boom starts was a nice and easy job.

Installation of Pedals

Tail Rotor: First direction change

Tail Rotor: 2nd direction change

Assembly of Tailboom(10.09.2006)
The installation of the two bearing holder inside the tail boom was not easy. For me the instruction in the manual was not clear enough. In fact I had to remove the two holders again (!) after installation to interchange them. I made a short sketch, just in case I have to do it again next time. -:)

 

Front end

Rear end, ready to install tailrotor gearbox

Waiting to be installed after engine installation

Installation of Collective and Cyclic (10.09.2006)
A very nice job to do! The quality of the parts is amazing. Each step is very well illustrated in the manual.

only the cyclic itself has do be connected

ready to connect to the engines cables

Collective, Cyclic together, view from left rear

Safety pin collective (21.10.2006)
These two bolts are turning with the collective.These nuts originally are metal self locking types. To be on the safe side I replaced them with castle nuts, drilled a hole and used a safety pin.

Right

Left

Rotax 912/914 line maintenance seminar (23.10.2006)
Being used to operate the Rotax 912 in my Kitfox I found it very useful to participate and spend one and a half day for these two engines, 912 and 914. (See: Franz-Aircraft) I got a lot of hints and tricks during the two days and I’m sure, it will make the installation / operation of the engine in my helicopter easier later on.

Do not turn this connector! (controls fuelpressure during high engine power)

Turbine with waste gate

Oel-pump, a second layer is connected on Rotax 914 for return oil from turbine

Preparing water/oil cooler (04.11.2006)
Preparation of the cooling system, waiting to be installed after engine installation

Watercooling (small Fan)

Oil & Watercooler (big Fan)

Both together, ready to install (this system will be replaced later on as a more efficient cooler-system is available)

Stby instruments/collision avoiding system) (05.11.2006)
Since I intend to install the Dynon FlightDEK-D180 instrument, I will need a liquid compass as back-up, a stby ASI and a stby Altimeter. The EWC100 is available from Ediatec (http://www.ediatec.ch/), it contains an obstacle database and also warns you of conflicting traffic (if the other traffic is also equipped with Flarm or EWC100 and closer than 2km).The digital display starts at a distance of 2km and below.

ECW100

EWC100, GPS Antenna, Data Antenna, Power Cable

Stby Instrument: ASI & Altimeter

Installation of battery holder (18.11.2006)
Installation of battery holder and connection of ground cable to the fuselage. 24th Nov 06: I received the callsign / numberplate from FOCA: HB-YNB (lateron battery installed more forward, below foot-area, CG issue)

Fuselage-side

Battery Holder with Ground Connection

Battery-side

Implementation/adaption of Dynon DEK180 (06.01.2007)
Instead of the Rotax Fly-Dat I will use the Dynon DEK 180. On first glance just „a minor change“ but a lot of work!

Working with the electric system

Dynon part of electric system

Engine cable with tags

Cabin installation with my brother Guido (01.04.2007)
This is the first try to fix the cabin onto the Fuselage. But to take a seat for the very first time is a lot of fun! We both together decided to loose some weight until the very first flight!

First try

Fixing cabin lower part

We both together decided to loose some weight until the very first flight!

Pick-up of 2nd kit, installation of mainrotor gearbox (01.04.2007)
We could pick up the 2nd part of the Kit March 26th 2007, everything worked fine and this time custom clearing was very quick. Content of Kit 2 was: Main Rotor Gear with Mast, Tail Rotor and the Blades.

My brother Guido, looking to be very precise

According installation manual: Tilt after installation: 2.5° forward and .5° to the right

Weight about 35-40kgs

Cabin (05.04.2007)
To adjust the cabin on the fuselage took a while, but all in all a perfect job they do at Heli Sport!

Cabin, lower part

Gear Fairing

Cabin, ready to fix

Adjustment of Canopy (21.04.2007, on my birthday!)
Fixing of canopy takes some time, a remaining gap will be covered later. Next step is covering the rear side of cabin with fireproof material.

Opening-closing hinge

Canopy closed

First closing-opening from inside

Fire Wall (26.05.2007, on my birthday!)
Material: 0.3mm,steel, Glue: GYSO (www.gyso.ch) Polyflex 444, Paint: Dupli-Color, silver, heat-resistant to 800° C

Fire-wall(Swiss Modification)

Ready for paintshop

0.3mm steel, ready to glue on

Fixing/adjustment of cowling (02.06.2007)
Before painting all the adjustments have to be done, also the cutout for the fuel filler cap. The inside of the cowlig doors are painted with heat resistant paint, silver, 800°C

Installation of tailboom, to have the center for the cowling

Rubber band installation

Painting (16.06.2007)

Rigging (04.08.2007)
Rigging of Cyclic Control and Collective.
Stick fully aft must bring a pitch up of 16°, stick full down must bring a pitch down of 14° on water level indication.
Stick full left must bring 9-10° bank, stick full right must bring 8-9° bank indication on water level.
Collective: Adjust to have a 2mm distance from the bottom in the slot. (Collective in full down position

Cyclic

Rigging of Cyclic Control

Rotor Head

Gear (19.08.2007)
Thanks to Ernst Baumgartner and Karl Hediger I have the best and nicest Gear you can have for a helicopter!
(later on I exchanged the gear with a two wheel-gear, not as nice, but more practicable)

Removable gear

Cabine, Oil, Fuelvalve (09.09.2007)
Image 1: Due to the narrow location, I had to find a possibility to drill the two holes: Stokys

Drilling with Stokys! (Seatbelts)

Covers: Fuelwindow, Radio, Shoulder Harness

  Watch the Chipdetector below, very proud of, got it from Viktor Strausak

Oil Reservoir/Intrument Panel/Thermostat Rotax (27.10.2007)
Dynon: With new software 4.0 installed, running on internal Battery
Rotax is selling this Thermostat, keeping water temperature at a fix point of about 80 C

Oil Reservoir installed

Dynon, running  on internal power

Original Rotax Thermostat

Cooling Kit available from Heli-Sport (28.12.2007)
To avoid hot water/engine temperature while hoovering during high OAT, Heli-Sport is selling a cooling kit to be used with water thermostat

Looking forward

Looking forward

Engine preparation for installation (10.01.2008)

914 as shipped, out of the box

914, carburator removed

Engine mount installed

Alternator installation (11.01.2008)
(Later replaced with EPA power alternator, rear installation)

Cooling fan installation (19.01.2008)

Cooling fan installed

View front-aft

Pully installation, including fan wheel(19.01.2008)

Oliver, my son, pully Installation

Cut „Halsmutter“ M8 to about 17mm

…..and install

 

Crew, ready to install engine (20.01.2008)

Marian and Oliver

Marian

Christina, the photographer!

Engine installation (20.01.2008)

…ready….

Ready to lift half up

Engine installed! (20.01.2008)

…installed, aft section…

…Marian, very concentrated…

Oliver and „Papi“

 

–

Cooling system (02.02.2008)

Left cooler, incl. Thermostat cooler

…see Rotax water Thermostat on the left…

Rotax Thermostat

Cooling system (02.02.2008)

Note additional distance to have enough room for steering rod

   Tube from waterpump to R water-cooler

Connection between R cooler to L watercooler

Clutch installation (02.02.2008)
Clutch: after tightening with 150Nm to max. 160Nm it must fit like picture 1 shows, if not, unscrew again and turn 1 or 2 teeth and try again. (this is to have tailrotor still connected in case something brakes in the coupling.)

It has to look like this after tightening with 150Nm

Alu stripe to hold against during tightening

Clutch, ready to connect tailrotor shaft

 

Engine Mount (02.02.2008)

Left, front

left, aft

Engine stabilizer, below

Oil system(16.02.2008)
Installation of oil-circuit system according Rotax 914 installation manual. To avoid damage due to vibration the oil pressure sensor is not directly mounted to the engine housing. Note that this installation needs an additional grounding of the sender (red wire)

Oil Reservoir

Oil pressure Sender

Remote installation of oil pressure Sender

Gearbox-oil-cooling 1 (23.02.2008)
Main gear-box oil cooling system

Oil-pump for main gear, view from left

…view from behind

…..view from right

Gearbox-oil-cooling 2 (24.02.2008)
Oil-cooler installation, in front of water-oil cooler. Oil runs from gearbox lower forward fitting to the filter, from filter to pump-IN, from pump-OUT into cooler and then from cooler back to the gearbox, upper rear fitting.

Oil filter (above), below oil cooler

Main gearbox oil filter Installation

Oil cooler

Fuel System Installation 1 (22.03.2008)
To have exact fuel available at any moment during flight, I decided to install a Return Flow Controller from Matronics.

The best Fuelselector available in market….! (Andair, England)

…how it looks from behind

Forward Flow Transducer

Fuel System Installation 2 (23.03.2008)

Filter, pumps

Pumps, fueltransducer, fwd and return flow

..then the line goes to the……

Fuel System Installation 3 (24.03.2008)

….to the carburator..

Also the fuel-return line has his Return Flow Transducer

Pumps, incl. fuel pressure sender for Dynon

Pick-up of „Rolling-Hangar“ (28.03.2008)
Today is another great day: Finally I could pick-up the „Rolling-Hangar“ together with my friend Noldi Schwaninger. The Klaesi team did a very nice job, see http://www.klaesi.ch/. The hangar is isolated and should keep the helicopter in a nice and friendly climate. Total length of the box is 7m50. Max. Driving speed is between 80-90kmh. Maximum allowed vehicle weight is 3.5 tons. There is still a payload of 1250kg available with the box mounted on the vehicle. (Remember: Helicopter should end-up with around 285kg)

Fuel System Installation 4 (31.03.2008)
Fuel-tank holder installation: The fixing with textile fixation straps is only for the temporary fixing of RH-tank good enough, for fix installation of L-tank a fixation with metal straps is required

Left tank protection

L-Tank holder, TCU behind

R-Tank holder, protection

TCU (02.04.2008)
Servo motor for waste gate, mounted behind LH tank holder

Gas cable, connected to governor/collective

L-Carburetor

R-Carburetor

Trim System (26.04.2008)
Longitudinal / side trim
The movable rod of servomotor has to line with nose up and down bar of cyclic. Before fixing make sure the movable servomotor rod is fully extended. Warning: do not power the trim motor only to extend the rod, rather turn it out manually until you hear the „click“ from stop-switch!
Side trim: good to drill hole for the bolt when still room available, before installation of battery, etc.

 

Longitudinal Trim

Side Trim

Preparation of winch Installation (03.05.2008)
Preparation of winch, remote controlled, to pull helicopter up/down.
Sutter GmbH, Elektro-Seilwinde 2000lbs-900/1800kg f. Quads Linhai ua
4 ST x 504358 KFZ-RELAIS FRC6BA-1-DC12V 1XEIN 150 A, 1 ST x 190904 2-KANAL-RF-FERNBEDIENUNGSSET – FG

 

Remote control, 2 ch

Whole set, ready to install

Rolling hangar, video system installation(04.05.2008)
Video installation:
2 ST x 855140 FUNK-ZUSATZKAMERA FÜR 853432
1 ST x 853432 FARB-TFT-RÜCKFAHRVIDEOSYSTEM FUNK

Service Bulletin 38 (10.05.2008)
SB 38, dated 5th May 2007 says:
The main tank (left) in the Charlie version is at a such distance from the exhaust manifold of cylunder 2 that it does not affect the tank by normal working. By supposition of a break of the exhaust manifold near the outlet of the cylinder 2, the exhaust gas at hot temperature could turn towards the tank, with negative consequences, therefore we suggest to apply a suitable protection on the surface of the tank near the manifold.
I decided to protect both tanks, R and L.

Left Tank, steel, covered with hi-speed tape

Additional Right Tank

Installation of Battery, master Relay and Shunt (20.07.2008)
Due to EFIS installation (lighter instruments) and due to advice of other builders I decided to install the battery forwrd, below the cabin floor.

Battery and Shunt

Battery Installation

Master Fuse (80A), Master Relay and Shunt

EGT probe Installation(11.10.2008)

EGT, M8 screw, locking: M3

TCU Connection (11.10.2008)
The Mapper-Card is between the engine and the TCU-Box[/fusion_text]

View from left

View from right

Corvatsch, 3200 m above sea Level

Lightweight Lithium Ion starter battery (22.12.2011)
Battery Fact Sheet Super B 5200, http://www.super-b.com/
Product Description
Lightweight Lithium Ion starter battery, 1.98 lb / 900 gram,
This newly developed battery is designed to replace the much heavier 10 to 12 Ah lead/acid battery. The super B 5200 is based on the safe Lithium Iron Phosphate technology (LiFePO4), better known as Lithium Ion.
The super B 5200 delivers up to 300 Cranking Amps.
The super B 5200 offers many advantages over conventional 10 to 12 Ah lead/acid batteries:
Weighs less: as much as 80% weight saving; 1.98 lb / 900 grams;
Recharges many times faster: within 5 minutes after starting your engine the battery will be recharged;
Is much smaller: 1/3 or less of the space; 4.49 inch, 3.2 inch, 2.4 inch (WxHxD) / 114mm x 81.25mm x 62mm (WxHxD);
Has a longer service life: more than 5 years instead of 2 to 3 years;
Has a low self-discharge rate.
Safety: Super B batteries are based on Lithium Iron Phosphate technology (LiFePO4). This so called Lithium Ion technology as used in the super B batteries is the safest Lithium Ion technology today.
Capacity
super B 5200 refers to 5.2 Ah (Amps/Hour), which represents the real nominal capacity under maximum continuous load. How different this is from lead / acid batteries where manufactures provide a 20 hour rating. For example the 10 Ah lead / acid batterie can be discharged over a period of 20 hours with a 0.5 Amp load. This is not very practical, as the same 10 Ah battery discharged with a 2,5 Amp load, for example a 25 Watt light bulb, will yield no more than 2.2 Ah of energy. The lead-acid battery, therefore, has less capacity when the load increases, which means that you can start more often with the super B.

See the Difference!

Before

After

Cabin Heater Installation (15.01.2012)
To have it nice and warm an Eberspächer B1 LC Air Heater is installed.
To compensate the additional weight a lightweight Lithium Iron starter battery,  specially developed for motorcycles, jet-skis, snowmobiles, ATVs and Quads was installed.

View from right below

Air Inlet Cabine, R, very important: take the air to heat from inside the cabin as well, if not, heater will overheat and shut down! ( due to (almost) blocked airstream if the cabin is closed)

Control unit, ON/OFF and Temp selector

Status of the helicopter right now (February 2015)
Helicopter is upgraded to model Kompress Charlie 2 (EPA power alternator, water-oil heatexchanger, means new Thermostat and watercooler, carbon blades, carbon stabilizer) and I just made my highest landing you can do in Switzerland.

 

Video: Monte-Rosa Satteltole, 4’150m/13’615ft!