RotorWay Exec 162 User Manual

RotorWay International
Exec 162F Construction Manual
Section 1
Standard Construction
Procedures
Section 1
Page A
Procedures covered in this section:
Proper use of tools; general fitting and alignment procedures; aircraft (AN) hardware; working with 4130 steel; working
with aluminum; working with plexiglass; working with fiberglass; working with plastic filler (Bondo); painting and finishing;
plating and anodizing; Dzus fasteners and nut plates.
Cards used in this section:
None
Prints used in this section:
None
Templates used in this section:
None
Tools required for this section:
None

RotorWay Exec 162 Specifications

General

Brand	RotorWay
Model	Exec 162
Category	Toy
Language	English

Summary

1. PROPER USE OF TOOLS

A. Drills and Reamers

Proper use of drills and reamers for accurate hole sizing and material preparation.

B. Torque Wrench

Importance and selection of torque wrenches for precision assembly.

C. Dial Indicator

Use of dial indicators for main rotor blade rigging and shaft straightness checks.

D. Dial Caliper

Utility of dial calipers for precise measurement of lengths and thicknesses.

E. Protractor Level

Application of protractor levels for construction and rotor system adjustments.

2. GENERAL FITTING AND ALIGNMENT PROCEDURES

3. AIRCRAFT (AN) HARDWARE

A. AN Hardware Material Strength

Importance of using AN hardware over standard hardware store bolts for strength.

B. Elastic Lock Nuts

Proper use and thread engagement for elastic lock nuts.

C. Castellated Nuts and Cotter Pins

Application of castellated nuts and cotter pins for pivot and hinge applications.

D. Lock Nut Restriction

Avoid using elastic lock nuts on bolts with cotter pin holes.

E. Safety Wiring

Requirement for safety wiring bolts without locking devices.

F. Torque Specifications

Standard torque values for 3/16" to 3/8" bolts, nuts, and set screws.

G. Bolt Hole Alignment

Ensuring bolt holes are perpendicular and not oversized for proper load transfer.

4. WORKING WITH 4130 STEEL

A. Bracketry Fabrication

Cutting, bending, and finishing procedures for 4130 steel bracketry.

5. WORKING WITH ALUMINUM

A. Cutting and Bending Aluminum

Guidelines for cutting and bending aluminum sheets, including material thickness considerations.

6. WORKING WITH PLEXIGLASS

A. Plexiglass Handling and Sanding

Careful handling and sanding of plexiglass edges to prevent cracking.

B. Protective Film Removal

Instructions on when to remove protective film from plexiglass components.

C. Drilling Plexiglass

Recommended drill bit types for creating cleco holes in plexiglass to avoid cracks.

D. Windscreen Screw Holes

Drilling oversized holes for windscreen fasteners to allow for slight movement.

E. Crack Repair

Method to stop plexiglass crack propagation by drilling the crack's end.

7. WORKING WITH FIBERGLASS

A. Fiberglass Preparation and Safety

Safety precautions and necessary supplies for fiberglass application.

B. Fiberglass Mixing and Application

Procedures for mixing resin and catalyst, and applying fiberglass mat or cloth.

8. WORKING WITH PLASTIC FILLER (Bondo)

A. Bondo Application and Finishing

Steps for applying and finishing plastic body filler, including mixing and sanding.

9. PAINTING AND FINISHING

A. Paint Recommendations

General recommendations for painting aircraft components based on climate and material.

10. PLATING AND ANODIZING

A. Plating and Anodizing Services

Guidance on selecting items for plating/anodizing and using qualified service providers.

11. DZUS FASTENERS AND NUT PLATES

A. Dzus Fastener Components

Description of Dzus fastener parts: stud, grommet, and spring.

B. Dzus Button Installation

Step-by-step instructions and photos for installing Dzus buttons.

C. Nut Plate Installation

Procedure for installing nut plates using clecos and a drill template.