Vario Chinook XL

The new Vario Chinook XL, arrived in a large box with mechanics and some additional parts made by 3D laser powder sintering with excellent resolution.

We started a few days ago with the mechanics and everything it's fitting in place very nicely. I'm also using my Dewalt electric screw driver with the right torque limit to screw so many screws.

Propulsion installation. Massive Kontronik motor.

Main rotor shaft installations. In addition the side plate started to add strength to the cage structure.

We started to program the BD 3SX and using some initial setup from Vario directly. I created a tool for ease the alignment of the swash plates plus a bubble level that will ease the final pitch adjustments. In addition we decided to go for another option on the Kontronik KOSMIK with dual fans as California summers are getting hotter.

I was missing a part for the landing gear assembly bags, but Vario Germany quickly sent it back to me. While waiting, I began redesigning the rear wheel struts to include a steering option, similar to the full-size version. The prototype turned out well using my resin 3D printer. I still need to check the fitting and clearance, but once that's done, they'll be ready for machining. This addition will be a simple upgrade to the existing Vario gear.

I just finished doing some machining and all components working per design.

Prototype is working for rotation and compression! Servo placement will come later on this chapter.

We decided to go for a bigger ESC, as we fly in hotter conditions. This is the DuoCOOL KOSMIK 300 HV-I, 300 Amps.

Final test before I put the heads and I'm happy the ESC and Motor are working well. I'm also getting the telemetry active.

Development has commenced on the Vario Chinook XL fuselage! and in some cases we will 3D Scan to get some shapes to adapt to scale components.

The scale turbines are in including the dust off filters for special operations and IR exhaust! Also trying the MH side tanks version.

The slide platform project for the Chinook MH-47 has reached completion. A key aspect of the design is the side pax/crew door, which is required to slide in order to accommodate the fuel boom. This final iteration incorporates bearings. The search for compact bearings yielded impressive results, including the identification of exceptionally small bearings with a 1mm ID on Amazon, highlighting the advantages of leveraging design software for efficient and enjoyable prototyping is so freaking cool!

Fuel boom installed and required to do some modifications on one of the holders. Got my caliper to measured the original and redesigned on the CAD and a few hours later part was done on the resin printer. I also used my trusty laser for proper alligment.

A winch has been installed on the MH-47 and will be operational. Vario did a great job enabling the housing to be ready for a winch servo. Also, the mini guns have been installed with the crew, and 3D-printed M240 Bravos have been installed on the side back openings based on information provided by one of my dear friends! Oh did I mentioned the crew has already some animatronics!

Tons of sensors and front cameras added to the MH-47. Also testing with the Formlabs printer having a sand cast finish directly at the front sensor. Got also a FDM printer for some section structures I need to do.

Our first test flight is officially in the books, and I couldn’t be happier with how smoothly everything performed. Huge thanks to Stefan Reusch for sharing the setup information and the BD 3SX parameters—much appreciated.

One of my favorite parts is diving into the incredible telemetry data from Jeti. Here are a few highlights:

Hover current: 59.2 A on the motor pulling
RPM: rock solid at 854 RPM
Kosmic ESC temperature: 23°C
Motor temperature: 59°C
Amps pulling by the servos about 1amp

Tracking was absolutely perfect, thanks to some custom tooling I built.

The fuselage is nearly complete with all the scale details. There are just a few more areas to finish up before it heads to the paint booth.

Time for painting, weathering and some stencil markings.

Windshields installed and setup of uni lights all done! Getting closer

Test flight on the books! Post flight next to check everything before we take the MH-47 for some pattern work.

Yes, she is up in the air this 51 lbs beast and what a joy to fly.

Check this high quality flying video that was taken at our RC Field in California.