saves the day AGAIN!!! I had forgotten to get the foot
pedals for Airwolf, and nobody seemed to have decent ones in
stock! I called Dr. Tim, and he had ONE. He
graciously cast it, and sent me a pair of "Original Dr
Tim Hand cast foot pedals" They fit perfectly,
and here we have the pilots just settling into them:
I decided to add a rear wall to the cockpit, so the mechanics would not
be visible. First, I had to take the "nose" off my
mechanics to shorten it, as the mechanics were about an inch too
long. Fortunately, the Trex 700 has a removable "snout"
to mount the gyro, and the original rudder servo (which I have mounted
on the tail boom anyway)
replaced the aluminum part with the original plastic one, so I could
easily cut it down to size. A little re-wiring, and changing the
cockpit battery type shaved almost two inches off the front of the
mechanics! To get the shortest hi-capacity batteries I could find,
I ended up using batteries for RC Cars, as they are standardized to fit
the pockets the cars are designed with. I used a pair of 65C 5000
mA Thunder Power batteries as the cockpit draws a LOT of current!
I first used
some plumber's solder pressed into the inside profile of the
heli to get the outline of the fuselage
transferred to blue foam. A few iterations of the foam
finally resulted in the bulkhead shape I needed..
Plastistruct plastic to make the bulkhead, as it is for
looks, not structural integrity. I used a diamond
plate pattern on the cockpit side, and ran some reinforcing
struts on the mechanics side.
fit with room to spare...
and clear coated gives great reflections from the
instruments. I will "tone this down" a bit
by adding some equipment mounted on the rear wall. We
want it to look like a cockpit, not a Discotheque!
Moving on to
the exhausts, I had hoped to use the Cine-Scale exhausts as
patterns to cast parts out of bronze. Bronze would
have discolored PERFECTLY under a blowtorch, and been just
what I needed!.. Alas, the people I wanted to use could not
do the job in any reasonable time frame, so I decided to go
In order to paint a cylindrical surface evenly, I made a
turntable out of some blue foam and my power screwdriver:
Here is how
they came off the turntable after painting. Later I
applied a matte clear coat to protect the paint.
exhausts, these are "suspended" in the hole in the
fuselage, so again- I used epoxy putty to make supports that hold the exhaust in the proper
position. When "mixing" these epoxy sticks,
every time you fold them over in half, you double the number
of layers. Folding it over 24 times gives you 2^24 or
16 million layers, which only takes about a minute, and
gives you guaranteed molecular-level mixing. This is
the same type of procedure used on those nozzles that
automatically mix epoxies as you squirt them through a
nozzle, like Aeropoxy / Hysol called binary mixers.
Anyway- enough of this "glue tech"!
One by one,
the window glass goes in. I use window gaskets on
the main windshield and doors, as the pre-relieved window
glass does not quite match up to the panel openings. I
use Formula 560 to attach the windows to the gaskets and the
gaskets to the fuselage.
there HAS to be a pack of cigarettes (or two) in the
cockpit. Since they have impeccable tastes, the pilot
smokes the same brand of smokes that I do!
Anti-smoking people can express your displeasure by pressing
the <ALT> key and <F4> at the same time!
Here is a
view through the door into the cockpit.
And a head
And an video of everything we have
done in this session (and a wee bit more!):