A fully detailed build of an INTERCEPTOR 400 Helicopter 
complete with the Alien Command (Standard)
Auto pilot system

Page 2

CHOPPERADDICT SPECIALISES IN THE BUILDING, REPAIRING & 
SETTING UP OF R/C HELICOPTERS AND RADIOS

   

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A point to note is that there are other guides available for building this kit, one of the best I have found is by Anti_A, and this shows in pictures every step of the build, so I would recommend that you also download this PDF and use it alongside this guide.

My task here will in some cases be repetitive, but I also want to try to point out the pitfalls that you can easily fall into when assembling this kit.  Some are really very easy to get caught by.
Ok, the top picture is all the parts required to complete the main rotor blade grips and fit them to the rotor head casing shown in the centre. NB - you are going to need one or preferable two 5.5 mm box spanners or nut runners to be able to tighten the nylock nuts on the outside of each end of the feathering shaft.

The lower picture shows the parts in more detail and in the correct order for just ONE side of the blade holder assembly.  

The best way to build this is to first of all put one of the nylock nuts onto one end of the feathering shaft, and to tighten it down just far enough so that the threads ONLY JUST come out of the top of the nylock nut.

Next, place one bearing on the feathering shaft, followed by the aluminium spacer and then the second bearing.  Now carefully insert the feathering shaft into the OUTER end of one of the blade grips, and slide it in as far as it will go.

You need to take care that you identify the two spacers correctly.  One is aluminium, and it is that spacer that goes BETWEEN the two main bearings into the OUTER side of the blade grip, as shown in the picture above.  The other spacer is a a plastic material, and that goes onto the feathering shaft immediately before you slide it through the main head post, as shown below.

Now get hold of the four rubber rings (called "O" rings or damper rings), and push TWO into the hole in the main mast top casing where the feathering shaft will go through it.   Repeat this with TWO rubber rings in the other side of the main mast top casing.

The main top head casing will now look exactly as shown on the left, with two rubber O ring dampers on each side.
The final move is to carefully insert the feathering shaft complete with it's rotor blade holder, and the plastic spacer, into one side of the main head casing, and pushing it all the way through as far as it will go.  You will need to use a 5.5 mm box spanner, or even a 5mm box spanner to push the feathering shaft through the rubber "O" rings.

If, as is quite possible, the rubber rings push out on the other side, just slide them back down the feathering shaft and carefully push them back into the recess in the main head casing.

Make sure you do not cut them as you push them into the head casing.

Assembling the other side is almost identical, except that you are going to be working the other way around, starting off by pushing the remaining plastic spacer over the open end of the the feathering shaft, followed by the second rotor blade grip.

The almost last thing to do now is to drop one of the bearings over the feathering shaft, followed by the remaining aluminium spacer, and then the last bearing.

Again, use the 5.5 mm box spanner to keep the feathering shaft from pushing out of the other side as you push the bearings & spacer in, as shown above.

Now using both 5.5mm box spanners or nut runners, slowly tighten the nylock nuts down, trying to ensure that both nuts have about the same amount of thread protruding through the top of the nuts.

Keep checking the tightness of the blade holder on the feathering shaft.  ONLY TIGHTEN them down far enough that the blade grips are not being pinched at all.  The blade holders MUST BE TOTALLY FREE TO ROTATE, but there should be no end play once the retaining screws shown in the next step are fitted and tightened down firmly
The last task in this section, but one that is easily forgotten, is to ensure that the outer bearings cannot slide out of the blade holder casing by pinning them in place with the four small screws provided, two in each side.

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