Mechanics for Vario R22 1:4

Due to the massive modifications on a standard Vario mechanic to fit the fuselage, the idea came to design an thrue fit mechanics for this R22 fuselage kit.
The setup of the mechanics has also a driven tailrotor in case of autorotation, witch is not the case with the standard Vario mechanics.
The mechanics has a 61mm with baseframe instead of the 44mm Vario, with adds stability to the frame.
The first chapter contains the machining of the main shaft hub for the main gear.

Machining of the main drive pulley on the 1st stage drive train.
The timing belt pulley is a HTD 3M 120 teeth version.
Starting with a drawing and a bare solid heavy pulley, so lot of weight to loose...
The autorotation unit is a Align 700/800 size unit.
Machining was done on a manual milling machine with a calculating measuring system, no CNC.

Frame design update
Upgrade the bearings of the torque tube drive, replace open ball bearings with closed and bigger ones.
Ball bearing plates for the shafts's are TSA origin

Turning and milling the final parts for the autorotation timing belt pinion.
Adaptor shaft 12mm/10mm for the drive shaft.
Clamping ring for the drive shaft.
All diameters are 0.01mm tolerance.
Drilling 3mm hole for the drive shaft.
All components are made of Stainless steel 306 material.
Original one way drive unit was Align origin.

Prototype Plexiglass mechanics frame setup.
Additional frame support on the backside landing gear for the frame baseplate.
Now some fine tuning on the frame shape according to the fuselage curves and scale interior space.

Machining the dome extention block compatible with the standard dome shaft.
Extended support for the long main shaft.
Adding 50mm in shaft height stability.

Prototype alu frames and ground plate.
Ground base plate and frame plates are 3mm thickness cut on a fiber flatbed lasermachine.

Final version of the R22 mechanics frame.
Added a counter bearing for the motor drive shaft.
Optimized holes and position for alround fixture of scale parts.
Adjustable motor position for timing belt tension.
Additional fourth ball bearing on the main shaft

Attach tailboom to main frame.
Install mechanics to baseframe.

Machining a ALU cup cover for the main shaft trust ball bearing.
So the grease stays in the cup and the bearing.
The AlU cup has a small clearance around the static trust bearing ring.

Final routing and wiring
ESC installation
Tailrotor install.
Swashplate assembly.
Navigation lights controller.
Optmised mainshaft clamp ring position
General FBL settings

Installing the front fuselage and mast cover.
Final assembly of the main shaft, swash and control rods.
Installing dummy engine.
Navigation light wiring.
Control rod adjustment.

Final assembly, and interior work finished.
Battery compartiment up front, accessible by removing the pilot and front cockpit console.

Owner : Hans Devos