helicopter assembly

Helicopter Assembly Details


1. Technical information

Type: Functional model to be constructed
Use: Construct in a workshop, for students of 12 and above

2. Elements used

Radiator: Material: aluminium (non-magnetic, smooth)
Treatment: Cut, file and polish
Attachment: Stick together with a two-component glue
After finishing: It doesn’t need any further treatment

Material: Steel rods (copper-plated covering)
Treatment: Cut, bend, file
Attachment: String together, light soldering
After finishing: It doesn’t need any further treatment

Material: Brass, copper and zinc alloy. Good, hard electrical conductor
Treatment: Cut, file
Attachment: Light soldering
After finishing: It doesn’t need any further treatment

Material: Copper, non-ferrous metal. Ductile and a good electrical conductor
Treatment: Cut, bend, file
Attachment String together, glue with a two component glue
After finishing: It doesn’t need any further treatment

3. Tools

Cutting: Saw for cutting metal. Note: Do not squeeze the saw while it´s not in motion. There is a risk of cutting yourself.

Filing: Choose the tool most suited to the job. In this case fine files. Note: Only press the file when it’s moving.

Sticking: We recommend a two component glue with a fine cap. Follow the makers’ instructions.
Adhesive tape.

Soldering: Use a 60W soldering iron or blowtorch
Clean the surfaces to be soldered, use paint stripper or solder with an incorporated paint stripper.

4. Material provided
Application Material Quantity Measurements Drawing
Cabin, Rotors and landing 1- Metal bars 7 Ø 2X500mm
2.- Runners Brass tube 1 Ø3/0,5x100mm
3.- Brass pulley 2
Radiator/Support 4.-Copper sheet 1 0,8x80x150mmor


5.- Aluminium tube 1 Ø25/1x200mm
Propellant 6.- Peltier cell 1 5x30x30mm
7.- Motor 2 Ø 25 mm
8.- Siren 1 1-12 V
9.- Electric wire 1 500 mm
10.- Candle 1



helicopter pieces

6 – Assembly instructions

  • 6.1 Preparation of the lateral frames
    6.2 Preparation of the flight cabin
    6.3 Preparation of the undercarriage
    6.4 Preparation and assembly of the principal and rear rotors
    6.5 Preparation of the supports for the candle, the radiator and the main rotor
    6.6 Final assembly
    6.7 Wiring and operating check
    Important observations:
  • The Peltier cell has a ceramic cover so is fragile.
  • Before soldering the metal rods you should remove any oxides from them using metal wool or sandpaper.
  • The generator is fitted for use in a model, not for continual use. You should leave the motor resting for 15 minutes after 10 minutes of use.
  • Don’t touch the radiator (the aluminium tubes and copper sheet). There’s a risk of burning.
  • In order to avoid all risk of fire you must handle the candle and match with care and avoid proximity between the helicopter and flammable material.
  • Don’t allow children to play with the helicopter unsupervised.
  • The rotor blades could be dangerous to small children so they shouldn’t go near the helicopter.
  • 6.1 Preparation of the lateral frames

    6.1.1 You will need 2 metal rods (1) of 500mm and two pieces of metal rods of 200mm (1a) to make these parts. Polish the ends of the rods
    6.1.2 Bend the two rods (1) as shown in the pattern on page 20, the plan of the lateral fuselage.
    Note: To form the rounded curves you can use a tube or bottle with an appropriate diameter. Keep checking the curves against those shown in the diagrams. Don’t use tools so that you don’t leave marks on the rods. At the same time you should make sure that the curves maintain the rods alignment, without forming lateral deviations.

    6.1.3 In order to connect he rods (1/1a) you will need to cut two 15mm pieces (2a) from the brass tube (2). You will place the ends of the rods in these tubes. Polish the short pieces to get rid of the burr produced by the sawing.

    Note: To avoid breaking the saw blade, saw using a light, even motion.

    6.1.4 The piece of metal rod on the right (1a) is joined with the uppermost part of the curved rod (1), through the brass tube. The tube will be soldered into place between the two.
    To do this make a mark about 7mm away from the end of one of the rods. Slide the tube along the rod to the mark and solder. The end of the other rod should be pushed into the tube until hitting the other one and the soldered into place.


    image 7


    6.1.5 The excess part of the rod (1a) should be cut down until it matches the length of the other. Solder these two ends together.

    6.2 Preparation of the flight cabin

    6.2.1 With the remains of the previous rods and the one new tod, prepare four crossbars (1b, 1c,1d, 1e), as shown in the drawing. Polish the ends.


    6.2.2 Transfer the alignment diagram (p20) by cutting out and then pasting it to a heat resistant base ( thick wood, for instance) of a minimum of 150 x 200mm.
    Note: this base has to be heat resistant because the crossbars and sidebars will the placed on it and soldered together on it.
    step 11

    6.2.3 Place the aluminium tube on top of the alignment diagram, as shown in the drawing. Fix it to the base with adhesive tape.
    6.2.4 Always following the drawing, adjust the sidebars of the cabin and fix in place with adhesive tape. Align the side frames in such a way that there is a 12mm separation between them at the back.
    Note: This 12mm space is important, because the rotor motor will be placed here later.
    image 12
    6.2.5 Place the crossbars (1b, 1c) on the base, as shown in the drawing. Their edges need to touch the side bars. Solder.

    Finished cabin

    Note: Owing to differences in crossbars and in angles, there could be differences between models.

    6.3.6 When the metal has cooled, turned the cabin 180º so that the upper part is on the base, as shown in the drawing. Adjust the crossbars (1d, 1e) and solder.






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