Build log of the building of the Vario
McDonnell-Douglas 900 Explorer
NOTAR tail rotor less helicopter
in UK Air support livery
Page 23

   

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         A built Vario MD 900 kit (by Vario)                                  The real thing in UK Air Support Colours

November 1, 2009

The day has started off with teeming rain, and the meteorological office has forecast winds of 70mph this afternoon, so definitely not a flying day of any form.

Did some more finishing work on the camera ball to get it the right height, and so that it angles down correctly when placed where they are fitted on the prototypes.

November 3, 2009

Had some great news from Vario today, the missing engine kit, head kit, titanium grease etc is arriving here on Wednesday - Yeehaaaaaa, I will finally be able to strip and rebuild the mechanics with grease etc, mount the engine and fit the exhaust system, and get the mechanics pod mounted into it's final position.

Once that is done, I can start putting the final paint coats on, attach the boom assembly, and start thinking about initial test flights.  First though I need to get the electronics to handle the blade phasing. Right now the choice is between Skookum and Helicommand Rigid, but there is a price differential of ~£200+ for Helicommand, but the nice thing is that it can level the helicopter back into a hover if you get it all wrong.  Skookum simply handles the rotor blade phasing problem.

I will wait for the owners decision on that one..... 

November 4, 2009

The RED LETTER DAY has arrived.  The remaining parts have arrived from Vario.

So the first task was to get the box cutter out and open the large box to see what I had to play with now.

The results are shown below :-

Now that is what you call an engine for this helicopter.  It is a Webra 0.91 2-stroke that 
can be run without any nitro in the fuel mix. 
It is pretty high revving, and gives a lot 
more torque than the original OS 0.70

The Stanley knife is there to give scale 
to show just how large the exhaust muffler is.

Here is the engine in all its pristine glory

Larger engines need large Starter motors, 
so I elected to go for the Vario Starter, 
plus the extension to poke up from 
the belly to start the Webra.

Several hours later, and a lot of hard work, the motor is fitted in place, the main gear and gearbox greased with the special Vario Titanium grease, which is indeed VERY SLIPPERY stuff.

Check out the size of the fan at the bottom right - that has to be running at 15,000 rpm to create sufficient airflow to control the NOTAR tail...

Well, the owner wants 2 pilots installed, so here is the chief pilot. His flight suit is going to have to be turned black somehow as he is supposed 
to be a UK Air Support pilot.

And to finish off with, a picture of the now 
complete mechanics assembly, without 
the tail exhaust fan in place.

Main rotor blades - 600mm each 
1200 mm diameter

FIVE of them as well=10 bolts to fit & remove them

Scary looking things eh ?

So, I now have pretty well most of the parts needed to complete the build, apart from the rotor blade phasing unit, which it seems is going to be the HeliCommand Rigid system, which not only provides the required blade phasing software, but also all the auto pilot features that make HeliCommand famous.

So once all set up, we should be able to lift her off the ground, and then take our hands of the sticks and leave her alone to hover all by herself. - Great Stuff.    

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