Time for Machinery:

This is definitely a very rewarding time of construction. To make it more fun, Kevin decided to get the doors out of the way first. I had heard that the doors were quite difficult to fit but again there is a process, which is really more painstaking than difficult. They fit into a frame, are riveted, sanded, filled, sanded and so on. You mark out where the paint finishes and fit them to the aircraft, drill and fit the hinges. Then the doors are ready for the paint shop : you can put them aside and go ahead with the fun stuff !

The secondary drive is fitted. This needs careful aligning, with its nearly parallel shaft actually offset from the rotor mast by 0.1 degree to the rear and 0.1 degree to the left, again with the digital protractor, which can measure that accurately. Rotorway have carefully designed the assembly process so that this kind of accuracy is possible with the mechanical adjustments available; which I think is quite an achievement. Although it's called a secondary drive; it's driven by the engine and then drives everything else -- main rotor, tail rotor, radiator fan, alternator, etc.

The engine is installed next. This is dragged under the airframe, still in the remnants of its box and hoisted into position with two straps. Kevin usually does this on his own and with two of us, it was easy. The main weight is taken on the bottom engine bearing, the engine being vertically mounted and a torque link stabilises the upper engine. The exhaust is bolted on, which we painted black, after lagging the stainless steel with a thick, heat resistant tape.

Unusually, this engine is liquid cooled and the fan housing is made up separately by cutting, sanding and riveting fibreglass parts. The fan and large radiator are installed and the unit is then mounted to the airframe. Drive shaft, 2 pulleys and 2 belts are fitted. The alternator, electric water pump, oil tank and coolant tank come next, along with another belt and fluid lines. All components are of an obviously high standard. An American built alternator is rarely seen! The welded oil tank (which incorporates an internal cooling radiator) is a beautiful piece of metalwork.

Fitting the 2 main fuel tanks and brackets comes next, although they will be removed to allow better access to the machinery, until final assembly. A long range fuel tank will also be fitted later, under the pilot's seat. That's the left seat in this helicopter, as the rotor rotates in the European direction (part of the engine heritage), rather than in the American direction. I prefer this, as the collective is better placed and I'm more used to flying from the left seat anyway.

Next, we will fit the body again, to ensure it does fit around all the metalwork, with the appropriate clearances.

The door frame.

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