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Safari Helicopter Construction
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Date:  5-24-2008
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Installing Blade Tip Caps

My Safari is still in the interior shop so I'm a little limited in what I can do in it's absence. I decided to prep the blades for balancing.

The first step was to cut the tip cap profiles from the provided sheet stock. I used a vertical belt sander to finish out the shape of the caps after the rough cutting. The blades came with two (?) #8 flush head screws for both of the tip caps. I decided to replace these with button head screws in case there was a need to add a washer or two during balancing.

The blades came with the rear most screw hole tapped. I had to drill and tap the front hole on both blades. The caps were sealed in place using a 3M water-proof adhesive sealant after applying alodine to the bare aluminum. I used a plastic spacer and some masking tape to hold the cap flush against the blade end while the sealant cured.

I'm going to ask the factory about providing a small vent hole in the cap. I understand that some of the earlier curved tipped blades had a vent.

UPDATE: The factory has confirmed the need for small vent holes in the tip caps to allow the blades to breathe.
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