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Bills Safari Adventure
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Date:  10-1-2011
Number of Hours:  7.00
Manual Reference:  
Brief Description:  Tail Rotor Drive Shaft and Floor

Back to work. Between playing golf(Sand Hills, Prairie Dunes, Flint Hills and Karsten Creek) I have not gotten much done. Also I have been waiting on a new hone to arrive. All here so lets get started. Thanks to my friends at Kice Industries I have a wide assortment of shims for the Tail Rotor Drive Shaft bearings. They have a brand new Laser and were happy to cut me some shims. Photo 1 shows the assortment. Their laser does not work very well on the 1/2" thick stuff. I used it planning on making one shim of the proper thickness after doing a trial set up with the thinner ones. We will see if I get around to that.

Next up in Photo 2 is honing the bearings to size. The supplied tubing was as much as 0.002" larger than the bore of the bearings. There was no way to beat them on. I pulled out my trusty Sunnen P180 Honall and had at them. I did not have a mandrel the proper size so I had to buy one. I got them all to a sliding fit in about 30 minutes.

Photo 3 show my alignment procedure. I used a self leveling laser that shoots a line. I put a floor jack on top of my transmission shipping crate and jacked up the rear end until the laser shot right through the center of the drive coupling and the tail rotor gearbox. This established my overall level. Then I went to each bearing with a lathe tool used for setting cutting tool heights. This little tool has a V on the back so it centers on the shaft. It also has a level on the top to make sure that it is level.

You can see the red laser line going down the middle of the shaft and half of the width of it is shown on the lathe tool. Half the laser line in on the tool the other half is burning a hole in my thumbnail. My shims worked perfectly.

Tomorrow I will take it off and weld in the insert at the back and drill/ream the hole for the rear drive coupling.

I also got my floor installed. This is a big deal as it means that I am finished undernearth. No more wiring or anything else. The bottom of the instrument pod got screwed down and I
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Tail Rotor Shims

Tail Rotor Shims

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Honing the Bearing ID

Honing the Bearing ID

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See the Red Line on the Tool

See the Red Line on the Tool

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