How to make a DIY helicopter

Flying a RC helicopter is an elated experience. A RC helicopter which provides the pilot a complete access to the three-dimensional space is completely unique. There are generally two types of micro-helicopters: one operated by gas and the other by electricity. The later is very clean and do not emit any noise unlike the former. For making it, one requires few mini high speed servos, standard dc motors and a bit of engineering skill which might be a bit challenging. Also the quality of the resources will determine the cost. Time required may vary from person to person.

Home-made Remote controlled Electric Helicopter

1. Making the main body

The circuit board (after removing the copper layer) can be used to make the main body, which is to be cut in a rectangular shape with a hole in the middle for the main shaft holding tube. It can be made from a plastic tube and two bearings, which are to be installed at both ends of the tube. This completes the basic step. Next step includes installing the gear as well as the motor. One can drill holes in the gear to make it lighter and to make it look better. The tail boom is fixed to the main body with 2 screws and some adhesive. 2mm carbon rods (having 4 holes drilled in it) are used for the landing gear. Instant glue should be used to stick the rods first, and then epoxy adhesive can be used to make it stronger. The skid set is made from balsa.

2. Making the swashplate

This is a bit sophisticated and it requires a ball bearing, a plastic spacer, rod end set, aluminum ball and ring and epoxy adhesive. After cutting the rod end set into a round shape, it should be inserted into the spacer. Two holes are to be drilled on the plastic spacer in order to house two screws for holding the ball linkage. The swashplate should be fixed on the main shaft by applying some glue between the aluminum ball and the shaft.

3. Making the rotor head

The circuit board should be used to construct the rotor head which should be sturdy enough to withstand any vibrations or it could be dangerous. The control system can be constructed by using the Hiler system. One should start from the middle part, which is a 3mm collar that can be fitted to the main shaft. A 1.6mm bar is inserted horizontally into the collar, making the rotor head movable in one direction. There are two holes just above the collar to house the flybar. Instant glue, followed by tiny screws, should be used for sticking the parts together.

4. Making the cyclic control system

The metal bar should be arranged perpendicularly to the flybar for holding the metal ball of the ball link in position. After shortening the rod ends, use a metal bar to stick them together by also using epoxy adhesive. Also an "H" shaped anti-rotating unit is a must for the control system. It helps to keep the ball link in position. An anti-rotation unit (a small board with 2 pins inserted on it) is also needed to stop the lower half of the swashplate from moving.

Making the tail rotor is easy and hence is not mentioned.

Now some quick tips:

1. The servomotor is very important for building your helicopter (as this will assist the helicopter to fly). It is available on e-bay.

2. Also the rotating blades of the helicopter have to be powered by either an engine or by an electric motor.

There is a possibility of generating a spark from the tail which can happen with any RC helicopters with T-Rex 500 and Spektrum receivers. To avoid this, coat the entire tail with silicon spray.

Though this is fun, this should be handled with extreme care. Enjoy and happy flying.