| What A Cool Heli! | ||||||||||
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Please Remember, ALL Information Here is for Sharing and NOT for Profit! Please remember to LINK to pictures instead of taking them from my site. Thanks! |
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Protech Shogun (Zoom) 400 |
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| - MY SETUP - | |
| Heli | Shogun 400 (same as Zoom and Dolphin) |
| Motor | Himax 2020-4200 Brushless from |
| Transmitter | JR 8103 FM w/ Breg-5 DPS II Receiver |
| Pinion | 9T |
| Servos | Cyclic: Hitec HS-55; Tail: Hitec HS-50 |
| Gyro | Futaba GY-240 |
| Battery | 3S Li-Poly 1200 or 1500 mAh |
| Blades | Helihobby woodies |
| ESC | Castle Creation Phoenix 25 |
| Charger | Apache 2500 |
| Connector | Deans mini-connector |
| Modifications | Belt Drive Setup |
| - LIKES - | |
| - Size is good, not to big or to small | - Pre-bent pushrods, |
| - Overall excellent design; simple and straight forward | - Nice simple pitch setup and smooth with minimal effort |
| - Standard size ball links | - Drop in Brushless replacement |
| - Nice foam blades, pre-balanced | - Autorotation included and ball in swash......smooth! |
| - No glue! Just nuts and bolts (YEAH!) |
| - DISLIKES - |
| - Landing gear is a joke! Designed to fit the shipping box not heli | - Poorly cut canopy. Again, pre-built; I rather be responsible for messing it up :) |
| - Poorly made tail gears, strip easily | - Tailboom supports are way to soft |
| - Main gear on mine touched main frame (do to slight wobble) | - Seems difficult to get full +10 -10 pitch range (have not played with it yet) |
| - Pre-built. (just a personal thing). I rather build the heli myself | - Difficulty getting some parts still |
 Bought One! Here is my Shogun 400! Just from a glance it looks impressive! Straight forward and simple. June 15, 04 |
 Himax brushless compared to the 370 size motor. Much smaller in diameter, same length and almost same weight. Power, that is another story! |
 My main gear wobbled a bit (no prob) and the cutout in the frame is for a "dead on fit." I cut slots (larger then I anticipated) so the gear does not rub. |
 I used the Hornet servos for which I cut the mounts. To solve this, I used Trinty Double-Side Tape (RC Car) and placed it on all sides of the servo. I then unscrewed the frame, placed the servos at the height needed and sandwiched them in. The fit is excellent with very little wiggle! |
To help secure the servos from tilting, I bent |
 For the collective servos I bent the same thin aluminum and sanded the servo case down. I then CAed the aluminum to the case at exactly the space I needed.. To add insurance, I wrapped the case with one piece of electric tape. Drill some holes and its ready to mount. |
 Boil the Landing Gear Nice landing gear but the width of the stance is a joke. I boiled the entire landing gear assembly and then set a heavy pot to smoosh them. I did bend the corners by hand a little and now the stance is useful. |
 Handmade Heat Sink CLICK HERE to see how this heatsink was made, and the other 3 :) 6-19-04 |
 For now I just went for simplicity. Thin aluminum bent using double side taped for the servo mount. For the pushrod, I used 2 mm carbon. The ball link is from the hornet as well as the ball (cut from a part) and drilled out to accept a tiny screw! |
 One Pinion Instead of the two, I am trying one 8 tooth pinion for now. Place it at the bottom of the motor shaft to turn both gears. You will need to extend both motor holes to have the motor line up correctly. Also... |
 Flipping the Tail for 1 Pinion Use For one pinion use you will need to flip the tail gear around. Just pull it off and flip it around to get the correct tail rotation. Simple. |
 Here is the underside showing the Phoenix 25 Double side taped and wires held by twisty-ties. |
 My antenna mount Remove the deans from its heavy mount, drill 4 small holes and use tiny wire to secure the antenna. |
 Right side, almost there! Just need to make a battery extension tray! Coming soon! |
  Here is the full heli! I used some of the stickers and painted the heli and paddles using Kylon gloss yellow. Came out pretty good :) |
 The swashplate can come apart and there is an easy fix. Put some 2 mm screws in the preexisting holes to keep the parts from separating. Just make sure the heads of the screws hold the bearing's rings. Hitec servo screws also work as well as the boom support mount screws. Just use something. |
 Lighter Paddle Holders I turned the original steel paddle holders . The original where 3.1g without the setscrew and after a little bit of cutting I was able to get them down to 1.5 grams each. Much nicer! |
 Some how the pin in the pitch plate got caught up and flipped the bellcrank over the tail shaft! I luckily was not to high and got it down. I decided instead of making a new pitch slider I would use the Hornets! |
 Again, I have somehow stripped the gear that goes to the tailrotor. I have the mesh "tight" but no go. Time to learn how to cut gears? Lets get started :) 6-30-04 |
 Custom Tail Rotor Mount Here is my tail servo mount. Again, I cut the mounting tabs off when I had them in the Hornet. To fix this I cut a piece of carbon fiber that just fits the servo. The aluminum mounts just slide over the boom. They only weight 0.7 grams and a tiny drop of CA holds them. 7-1-04 |
 My First Gear! Check it Out! CLICK HERE to see how this gear was made! Unfortunately they did not last long :( 7-5-04 |
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My
Belt Drive Version with Minimal Frame Modification |
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KEY TO THE WHOLE MOD! |
 Hex Shaft I used the Shogun's tail rotor shaft but any Allen wrench that fits very tightly should work. I drilled out the holes to about 1.75 mm before pressing in the shaft. Use some CA for a "permanent" and secure bond. Very tight fit. |
 Here are the parts together. Mount the horn on the "spline" and then press them in together. Make sure you press in the the parts so the servo horn turns out to be 90 degrees to the cyclic mechanism. The smooth part from the "spline" will rid in the frame and it works very well. |
 Drill one frame hole to 3.75 mm and gently open it for smooth operation. Put it all in and attach the horn. On the other side just replace the screw. It's still not a perfect straight shot to the servo but you can use a ball link now. NOTE: A small wheel collar or retainer clip should
be used to make sure the horn does not pop off. |
 Here are the parts from SDP-SI Main Pulley is 36T MXL |
 Gear Assembly Turn the pulley to about 3.5-4 mm thick. Bore the hole to 13.84 mm and cut the flange so it fits inside the frames (about 24mm in diameter or so) KEY: Flip over the main gear and also tap out the one-way bearing and flip it over for correct rotation. |
 Here are the tail parts. The hole is 3mm so you will need to make some adaptor for the 2mm shaft. I made one out of aluminum and will CA for now. NOTE: Plastic tubing as bushing works better as it expands and grabs. |
 New Tail Shaft I made a tail rotor shaft out of a Raptor's link. It is 2mm and needs to be filed down to 1.97mm. It is quite easy to do this by hand using an ordinary file. Just file as you twist. |
 Bushing Placement Here is the complete assembly. The space for the pulley is 12mm. Again, I used tubing similar to the one the Shogun's tail pushrod runs in. Drill it out just under 2 mm and shove it on the tail shaft. CA if you like. |
 Here is the assembly ready to go with the belt on. Take some time and it will be very smooth. |
 Full back cyclic. No problem here! Again, the key is the elevator assembly needs to be modified for the pulley to have enough space. |
 Here is the view from behind. I still need to add some bearing guides. More then enough space. |
 Full forward No problem here either! |
 I drilled and tapped for 2 mm screws to hold the 36T pulley. Next time I will drill only 3 holes 120 degrees apart. Held very well.
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 So you don't have to move the boom up, cut the BOTTOM of the frame on both sides, level to the top of the motor mount. It moves the gear down 1-2 mm and centers the belt well. |
  Here is my guide mount for 2, 6x2x3 mm bearings. Put a nut under the bearing to keep them off the guide. Wanna cut your own? Get the DXF FILE CLICK HERE I have also added a picture of the layout but it is not to scale. |
 Here is the mount. I just need to cut the screws down and it's good to go. The carbon looks great! Awesome fit! |
 Here is the layout with the motor in. I used 2 washer to lower the motor a bit. The pinion is cut in half and is not in-between the belt as it looks in the picture. Make sure nothing touches! |
 SHE FLIES!!!!!! Awesome and very steady! Sound great! Much quieter then stock. 8-8-04 |
 First Landing in Grass The tail held great! No problem here. |
 Here you can see the grass stains on the tail blades. This modification has really made the Shogun awesome! |
PICTURE TO COME |
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| Elevator
Rotational Assembly Redone (This mode did not work out as well as the above one using the HEX shaft) 12-27-04 |
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 I used a GWS 2mm prop shaft (for the park flyers) and cut it down. Push the spline part into the hole |
 Since I had already drilled out the hole, I had to make a bushing to support he 2mm shaft. If your doing this for the first time you can just slightly enlarge the current hole. |
 Here is the arm I cut out of aluminum. Pretty rough but it works! |
 Here is everything mounted. I am able to use 100% of the elevators throw and the shogun feels great in flight. WHAT'S
NEXT? |
| Date | |
| Bought | June 15, 04; My 30th birthday present :) |
| 6-20 | SHE FLIES!! But just a little. I can't keep the one pinion gear from coming loose. Thanks Rick for giving me a pinion gear |
| 6-24 | Burned out the tail gear coming off he motor :( |
| 6-27 | My good friend, Rick C., to the rescue! He had an extra gear and gave it to me. 5 min flight today with tail twitches. |
| 6-29 | My pitch plate pin popped out but luckily I wasn't to high. The bellcrank flipped over and bent the tail shaft. |
| 8-8 | Belt Driver is a Success!!!! |
| 12-27 | Back up! Roll rate is still slow but the elevator is quick. |
| To RC Helicopters ! |  |
| To CNC Examples ! | |
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