RotorWay International
Exec 162F Construction Manual
Section 1
Page 1
Rev. 1 3/99
1. PROPER USE OF TOOLS
A. Drills and Reamers
1. When a very close tolerance fit is required, use a “D” drill (.246") for drilling 1/4" AN bolt holes. 1/4" AN bolts are
normally .003" undersize. The bolts will fit very snug and will have to be lightly hammered in place with a plastic
mallet. This method should be used only for 1/4" bolts that hold a pulley on a shaft, the bolts that hold the main
sprocket to the hub, and in similar applications. When the fit is less critical, a standard 1/4" drill bit should be used.
2. In order to drill a hole closer to the exact size, always start with a slightly smaller drill, then finish the hole with a
sharp drill of the exact size.
3. When attempting to drill 4130 steel, always use a slow drill speed and apply pressure. Drills must be sharp; a dull
drill will become hot and harden the material. Once the metal hardens it will be almost impossible to make the drill
cut through. In such a case, it will be necessary to heat the material with a torch until it is cherry red. Allow the
material to air cool completely before attempting to re-drill, this time with a sharp drill. (Do not quench.)
4. A reamer may be used for final sizing a precision hole to within ± .001". A good rule of thumb is to use half the
speed for reaming that you do for drilling. Use plenty of oil.
5. To drill out a rivet, use a drill the size of the rivet. Start drilling in the center of the rivet head and rotate the drill in
a circle until the head of the rivet comes off. Stop drilling and use a punch to remove the shank.
B. Torque Wrench
A Torque wrench is a must for precision assembly. If you do not already have one, purchase a 3/8" drive micrometer
type and make sure that it has a scale on it marked in ft.lbs. The main blade retention bolts have the highest torque
of any bolt on the ship and are torqued to 70 ft.lbs. Therefore, it is not necessary to have a torque wrench that reads
over 100 ft.lbs. A heavier torque wrench will not give as accurate a reading at the low end of the scale (6 - 10 ft.lbs).
C. Dial Indicator
A dial indicator is an absolute must for main rotor blade rigging procedures. The indicator must have a dial that reads
in .001" increments, along with a magnetic base and gooseneck to hold it.
A dial indicator can be used for checking the straightness of a shaft as follows: support both ends of the shaft in “V”
blocks. Place the point of the dial indicator on top of the shaft in the center. The total indicated reading (TIR) for a 360
degree rotation can be noted.
A dial indicator is also useful for checking relative height settings. Its main use on the EXEC 162F will be setting lead/
lag adjustments on the main rotor system.
D. Dial Caliper
A 6" dial caliper with a needle travel of .100" per revolution is a very useful tool for checking precise lengths and
thicknesses.
E. Protractor Level
A protractor level is used throughout the construction, and also for rigging procedures and rotor system adjustments.
A quality protractor level will read in increments of 1/2° or less. An electronic protractor is a good option. In order to
check the quality of the level you are purchasing, zero the bubble and place it on a level surface. Rotate the level 180°
to the surface and see if the bubble maintains its centered relationship. Also, the lines on each side of the bubble
should be as close as possible to the end of the bubble.
2. GENERAL FITTING AND ALIGNMENT PROCEDURES
A. Do not force bolts into holes that are undersized. Pass a sharp drill of the appropriate size through the hole first. Do not
use excess force to drive a bolt in place with a hammer. Whatever you put together will at some time have to be taken
apart. Bear this in mind as you complete the construction.
B. Fit shafts and mating parts carefully. If a bearing does not slide onto the appropriate shaft, do not hammer it in place
(it’s OK to tap lightly). Use 400 to 600 grit sandpaper to sand the shaft down slightly until the bearing fits. In most
cases, there will only be small burrs which need to be removed.
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