DFC head upgrade to 500ESP

[Deet]

Hi All

Just though I'd make some notes on what I need to do and the parts required to build a complete 500DFC head and fit it to an older (pre EFL/Pro) T500.

The first thing you need to realise is the DFC head upgrade kit is not a complete new head, it is a kit with only the bare minimum parts required to upgrade a 500EFL head. It could also be used on a 500Pro FB heli as an FBL head upgrade.

As such there are a lot of parts missing as the kit assumes you are pulling the old head apart to do the upgrade.

I wanted to build a complete head, and also see what other things may be required to fit it to the older style frames.

So first, The parts you will need:

The Kit (H50181)comes with a main shaft (much shorter), a head block (pre fitted with sleeve and dampers, the grip arms, and all the links down to the swash.

So you will need the following to complete the head:

1 set Pro Blade Holders H50150
1 Feather Shaft H50023 (you get two spindles AND one set of grip bolts/washers)
1 Thrust Bearing Set H50004
1 Damper Black H50022

The Damper set may seem weird, but neither the upgrade kit or the Grips include in them the brass grip spacer that goes between the dampers and the grips. The only way I found you can guy it is packaged with the black dampers.

The head itself is easy enough to build, just as you would normally. I won't go into those details here.

NOTE the control links and grip arms come pre-assembled BUT do not have any loctite on then, so make sure you strip down and loctite everything. Also don't forget the grease the thrust bearings.

That gets you a complete head. except for another minor issue. There is a new Jesus Bolt supplied with the DFC kit, but this is the lower Jesus Bolt. The upper Jesus lot on this head is slightly shorter. Its the same Jesus bolt used in the various FBL heads. Luckily I had a spare, I am not sure how you would get one as a single part.

Now for the ESP upgrade you will also need a set of Pro Main Shaft Shims (H50157)

The reason for this is you are going to be using the new main shaft, and on the Pro/EFL models the main shaft has a fixed ring instead of the adjustable collar on the older main shafts.

So the next step is to pull the head off the ESP, then pop the servo links off the swash and remove it from the main shaft. Then undo the lower Jesus Bolt and pull the main shaft out.

Take the thinner of the two shims (they come in two sizes in the pack) put it over the lower section of the new main shaft and fit it to the heli. Fit the Jesus bolt and then see if you have any up/down play in the main shaft, if you do then try the other shim. I actually had to use both. to get 0 free play.

Once that is done refit the swash then the news head can go on the heli.

Now reset 0 pitch, check your FBL controller settings and enjoy.

Before (the 3G FBL head with the short main shaft)





And after

[Mateyhv]

Thanks for the tips Dave! I am not planning to install that head however the only thing I am not very comfortable is the main shaft fixed ring and shims. In my opinion the older method was not bad at all.

Hope you can tell us how it performs vs the older 3G head.

[Deet]

I would rather stick to the old collar too, but that's just how it is

BTW I also did some testing of how much movement there is in the head, I couldn't make it flex...

[Lighty]

Looks great but seems pricey after all the additional pieces.

Actually I added it all up to about $120. Would that be right Deet?

[Deet]

its cheaper than the old Align FBL head

[Mateyhv]

Originally Posted by Lighty

Looks great but seems pricey after all the additional pieces.

Actually I added it all up to about $120. Would that be right Deet?

I also feel its too expensive. I think its a matter of time to see other brands lowered heads out there if this one is a success.

[snjbird]

I am glad to read your report Dave, I look forward to your review of the flight performance!

Do you have any way to video it?

[Deet]

will see what I can do re-video, but as there isn't a prior one not sure the point, it will be a heli flying

[Jose5x5]

Deet, what type of frame is that in the photo.doesnt look like a 500esp

[Deet]

Originally Posted by Jose5x5

Deet, what type of frame is that in the photo.doesnt look like a 500esp

read my signature

[wanderer56]

Yep............ I asked Deet about that frame earlier. It's a one-off from a top secret supplier that no longer makes them in the Black Forest in Bolgemia!

But it is a cool and aerodynamic looking frame.

[Deet]

actually there are 4 of them, and he now lives in the UK

http://www.archeli.com.au/forums/sho...d.php?t=142994

[snjbird]

So you can't get the frames any more? too bad it looks super cool!

[ragge1]

Originally Posted by Lighty

Looks great but seems pricey after all the additional pieces.

Actually I added it all up to about $120. Would that be right Deet?

hmmm $120 , ok then that comes to the point I made in another thread as you get a complete Traxc head for $120 and use your original mainshaft

[Deet]

Originally Posted by ragge1

hmmm $120 , ok then that comes to the point I made in another thread as you get a complete Traxc head for $120 and use your original mainshaft

the $120 includes the new mainshaft and the head ends up being about 30mm lower than the Traxc.

Also if you buy all those align parts you will have spare dampers and a spare featuring shaft.

If you weren't interested in building it as an entire head, and are prepared to "upgrade" an existing ESP head, you only need the kit, the grips and the spacers, which is under $100.

I did this as a exercise to see what exactly would be required if it was a complete build

I already had bearings, spacers and spindles in the spares box anyway, so it wasn't that big a deal for me to do it this way.

And now I have a complete spare FBL head.

[Lighty]

I'll definitely do the upgrade if I crash. Thanks for the info Deet.

[AlphaCharlie]

Love the lowered sleek look Deet. I am very much looking forward to seeing it fly.

[Deet]

Just a note

I have just found out from the Aussie Distributor that the reason for the delayed shipping was that Align was sending the correct Jesus bolts to be added to the kits.

A careful inspection of the post pack found the correct Jesus bolt in the bottom of the pack, lucky I hadn't emptied the garbage bin yet

AC. helifest if not sooner..

[Deet]

Finally got to give it a good fly yeaterda

All I need to say is this:

Complete 500/ESP FBL head for sale, includes FL main shaft, and a spare.

[Glass Monkey]

Originally Posted by Deet

Finally got to give it a good fly yeaterda

All I need to say is this:

Complete 500/ESP FBL head for sale, includes FL main shaft, and a spare.

+1, i upgraded from flybarred head, cost me about $95, cheaper and, imo, a significant improvement on the standard align fbl, and...

complete fb head for sale, along with a complete 450 pro fbl head when they come out with one for my little trex (already lowered the head of my mcpx, lol)