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

Page 8

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

   

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The main frames

UPPER FRAME ASSEMBLY

Now we are going to start on the main frames. There are two separate parts to the main frames, called the upper and lower frames, which are bolted together eventually.

The first pack of parts required to start building the UPPER frame assembly.
It is a good idea to split the different screws in separate piles so that you do not use the wrong ones in the wrong places.
Shown on the right are both of the main upper frames, which are made from light but strong aluminium, anodised black.

Note that there are TWO BEARINGS already fitted into the frames. These are for the Elevator control arm, which we will fit later on.
Take the two plastic bearing holders (similar to those used for the tail driven gear assembly) and push a bearing into each one of them firmly so that it seats correctly in the bearing holder.

They should push in with finger/thumb pressure alone.
Next, fit a connecting ball to each end of the elevator arm.  As always, ensure that the balls can rotate freely when pinched up.
Now get hold of the other two plastic frame spacers that will go at the very back of the frame. These are used to hold the boom in place, so please take note that one of them has a plastic lug on the inside that is used to locate the boom to stop it spinning around when fitted. This frame spacer MUST be fitted on the INNER POSITION in the frame, and it must also have the lug on the left hand side of the frame.

Also note that these have a split at one end - the split ends will go DOWNWARDS when fitted to the frame, as this is how we will tighten the boom so that it cannot move later on.
Here is the RIGHT side of the frame with the outer boom spacer positioned and held in with one self tapping screw in the TOP (The top of the frame is nearest you in this picture).

This spacer is NOT THE ONE WITH 
THE LOCATING LUG ON THE INSIDE

Don't tighten this screw up all the way just yet.
Now attach the INNER boom support with one self tapping screw in the TOP hole only. Do not tighten it right down.

Make sure that the boom locating lug is on the left hand side of the aircraft.

This picture shows both spacers fitted to the RIGHT HAND FRAME, whereas the one above is shown in the LEFT HAND FRAME for additional clarity.
Now get hold of the tail driven gear assembly we built before. Lay the RIGHT SIDE frame down as shown on the right, and position the TOP of the tail driven gear assembly over the holes as shown.

Turn it over, and put two self tapping screws in to hold the top bearing holder in place in the RIGHT side of the frame.

Do not tighten these fully yet.
Use one more self tapping screw to hold the lower bearing holder n place on the RIGHT HAND FRAME.

Do not fully tighten these screws.
Now lets move on to the bearing supports for the main shaft and rotor head.

These are both the same, but please take note of the correct orientation of the bearings in the holders. Press the TOP bearing into a bearing holder, and then locate it in the RIGHT HAND FRAME side with two self tapping screws, ensuring the bearing is pointing DOWNWARDS.

Do not fully tighten these screws.
Now do the same with the second main bearing holder. Yet again, ensure that the bearing is pointing DOWNWARDS.
Let's fit the Anti Rotation bracket to the RIGHT HAND FRAME. It is held in position by two self tapping screws on each side as shown on the right.

You can tighten these screws all the way up straight away.
Get the canopy mounting arms and fit one on each frame, pointing outwards of course side.

Our picture shows it fitted to the LEFT HAND FRAME.

As you can see, it goes in the hole immediately in front of the Anti Rotation bracket we have just fitted.
Now we need to identify the cross shaft that fits into the two pre-fitted bearings in the upper frame side, and fit it into one side of the frame.

Our picture shows it fitted into the RIGHT HAND FRAME.  The elevator arm will fit over this to allow it to rock freely forward and backwards.
Find the other spacer (brass coloured), and screw this in place in the RIGHT SIDE of the FRAME at the very FRONT.

This does NOT USE SELF TAPPING SCREWS, but rather threaded bolts. Use thread lock and tighten it up fully.
And now the moment you have been waiting for all this time, we are going to bring both sides of the UPPER FRAME together.

I suggest that you start from the back, where the boom fits, and work your way forward, screwing all other assemblies to the LEFT HAND FRAME. using the same types of screws, and number of screws we have used in the instructions above.

Put the long bolts through the bottom of the boom holders, put a nut on them, but DO NOT TIGHTEN THEM RIGHT UP.

Make sure that ALL OTHER frame screws and bolts are fully tightened, and that you have used thread lock wherever a bolt goes into metal (CNC)

This is what it should all look like if you have done it correctly....

NB items

Don't put linkages in outer holes for learners, 3rd hole in is fine

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