Build log of the building of the Vario
McDonnell-Douglas 900 Explorer
NOTAR tail rotor less helicopter
in UK Air support livery
Page 3

   

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

September 28, 2009

As the weather continues to be gray and windy (again) I decided to complete the dry build of the basic mechanics so that I have a frame with mainshaft, swash plate, servos, gearbox and carbon fibre mounting base plate.

There are a few GOTCHAS at this stage of the build if you follow the diagrams in the Vario build documentation strictly.

The first I noticed was after I had assembled the frame with all the various spacers, all of which is quite fiddly, only to discover (later in the documentation) that the elevator servo has to be mounted from the inside of the frame, not the outside as is the case with the other three main servos.

So I had to strip the frame down again to remove the left hand side completely in order to access the servo mounting slot and mount it correctly so that the connecting rod is dead perpendicular up to the swash plate.

The documentation gives you the exact length of all the connecting rods between the servos and the swash plate, and these seem to be about right, at least for this stage of the build.  You can also see that the connecting rods for the aileron servos to the swash do not sit perpendicularly, as one would normally try to achieve.

One odd thing that I have yet to discover the reason for is two longish connecting rods that fit between a ball on the frame at the back and another below and forward of it on the external carbon fibre part of the frame.  As these two are already bolted together very solidly, the exact purpose of these rods is, as yet at least, a mystery to me

Here is the frame with base plate and servos mounted etc. The rotor head is just slipped on top for effect.  Pretty impressive rotor head ain't it ?  In fact, this comes fully assembled other than adding the ball connectors to each arm, which is nice.

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CLICK HERE for more pictures of the frame fully dry built...

The overall quality of the frame parts is excellent, as I would expect from Vario, and all parts are provided down to the countersunk screws to hold the carbon fibre base plate the the main frame.   

                 
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