Building a Vario Bell 230 1:7 800 size

Building a Vario Bell 230 1/7 800 Size model
Starting from a second hand fuselage
Installing additional glassfiber layer for sufficient groundplate stability.
Adding a Carbon / Kevlar layer for the Lipo compartiment.
Using Aerosyl to make a very thick and light filling epoxy compound.
Closing the existing swashplate hole, new smaller opening that fits the new rotorshaft position.
Restoring the alu retract control rod that was cut apart.

Installing the Trex 700 mechanics, using a 800 strech kit to get a longer tailboom.
Milling the Alu subframe to support the mechanics starting from a 60 x 60 x 2 mm Alu profile.
Using the existing mounting holes of the original carboside plates.

Modifying the tailrotor components in order to fit the tight space at the end of the fuselage.
Lowering the control arm by 8mm.
Tailrotor is installed on the left side of the fuselage.
New Sullivan style control rod for tailrotor pitch control.
Main rotor direction has to be changed from CW to CCW.

Modifying the rotorhead.
Changing the main hub, no arms needed in the new head setup.
New 3mm ptich control rods.
Machining the main shaft.

Fitting the tailrotor in the tight tailboom end space.
Merge the tailrotor bearing housing on to the fuselage.
Milling out the pocket for the tailrotor bearing housing in the tail fin.

Milling the upper side support profile for additional stiffness between the mechanics and the fuselage.
Using the original mounting holes of the carbon side frame.

Machining central piece for swashplate follower.
Using Align H70H009XXT control arm. (Tri blade head)
Due to the reversed rotation direction, the alu cross pieces may detach from the tube.
Securing torque tube end pieces with extra M2 bolt/nut.

Machining Lipo battery connectors (2 x 6 S)
The Lipo's will be installed left and right of the mechanics.
Installing BEC and capacitor backup unit.
Installing vertical stabilisers adding Aerosyl to the epoxy resin (thixotrophy powder, making the epoxy resin light, while creating more volume)

Maiden flight @ 1400 rpm, smooth and easy like a scale machine should fly.
Rock steady on the tail and head.

Installing turbine exhaust ports
Finishing work on the tailboom and put on the primer
Installing Lipo battery support plates.

Fuselage painted, now the details and lightning had to be installed.
Helicopter owner : Hans Devos
Paint job: Hedwig Lootens