HFX




	Helifreak Xtreme Conversion kit Assembly Instructions For

		For Align’s T-Rex 600



Introduction Thank you for purchasing the new Rotorworkz carbon fiber or G-10 eCCPM conversions frame for Align’s T-Rex 600 RC helicopter. We are sure you will be quite pleased with the performance results achieved after installing this frame modification. As well, you will begin to rely on the durability this frame possesses, further enhancing your flight enjoyment. Tools Needed Philips head screw driver 1.5mm Hex Wrench or Driver 2 mm Hex Wrench or Driver 2.5mm Hex Wrench or Driver 4mm Wrench or Nut Driver 5mm Wrench or Nut Driver “C” Clamp or Bench Vise Small scrap piece of hardwood Adjustable Squaring tool Supplies Needed Medium Strength Thread Lock Retaining Compound (Blue) High Strength Thread lock Retaining Compound (Red) Assorted Plastic wire “Zip” ties CA Glue (optional) Sanding block with assorted sand paper Parts included with this kit Depending on the kit you have chosen composite panel parts are cut from either Carbon Fiber or G-10 sheet material unless other wise noted (2) Frame side panels (2) Frame Doublers (3) Servo arm adapter plates Futaba (2) Servo bridge plates 1 each for Aileron and pitch servos (1) Servo Bridge plate for Elevator servo (22) Servo Spacer / Retainers (2) Canopy Pin Break away tabs (1) Receiver Tray (3) G-10 Main shaft Bearing block plates “(2) Top and Middle (1) Bottom” (3) G-10 Main shaft Bearing block Shim plates “(2) Top and Middle (1) Bottom” (3) G-10 Main shaft Bearing block Captive plates “(2) Top and Middle (1) Bottom” (1) G-10 Anti-Rotoation Guide (3) Servo Studs (brass) (3) 7mm x 3mm Flanged Bearings (6) 25mm Aluminum threaded spacers (13) M3 x 6mm socket head cap screws (4) M3 x 8mm Button head screws (4) M3 x 8mm Socket head cap screws (29) M2 press in nuts (13) M2 x 10mm Philips head screws (14) M2 x 6mm Philips head screws (13) M2 x 12mm Philips head screws (10) M2 nuts for servo arm (21) M2 Flat washers (15) M3 Nuts


	Begin Disassembly

		You do not need to do a completely Disassembly of your Heli in order to install this conversion Remove the head and main shaft assembly from your Helicopter as a unit Remove Electronics such as Receive, Gyro ESC, BEC Remove Tail boom, boom supports and mount assembly as a unit Remove all bearing blocks, frame spacer, and trays Remove Main shaft Bearing from blocks


	Installing Press In Nuts




		Figure 1


				Figure 2



		Figure 3

Locate (2) Side Frame panels, (16) Press in Nuts, “
Locate “C” Clamp tool and Scrape Piece of wood shown in figure 1
Installing Press in nuts in to side frame panels Can be done using a Small “C” Clamp and an small block of hard wood figure 2 we recommend adding Red thread lock to the spline portion of Press in nuts.

Install Press in nuts in the following places Figure 3

Red Dots = Press in nuts are installed from what will be the interior side of the frame (Flange faces towards you)
Yellow Dots = Press in nuts are installed from what will be the exterior side of the frame panel (Flange faces away from you)


	Installing Servo Bridge Spacers




		Figure 5


	Figure 4



				Figure 6

Locate Both Side frame panels, (6) 25mm long Aluminum Spacers, (6) M3 x 6mm Cap Screws, 2.5mm Hex driver or wrench, and Medium Thread Lock (blue) figure 4
On left and right side frame panel install (2) 25mm Aluminum spacers using the M3 x 6mm cap screws through holes shown in figure 5 note spacers for pitch and aileron servos will be mounted on the exterior frame side
Install (2) 25mm spacers on the left panel figure 6 note spacers will be mount on the interior frame side.


	Installing Elevator Servo




		Figure 7




		Figure 8




		Figure 9

Locate left frame panel, (6) Frame spacer / Retainers, (4) M2 x 12 mm Philips head screws and screw Driver figure 7
Optional (recommended) Glue (2) frame spacers together making one piece one for each servo side this will make assembly and future assembly easier figure 8
Install elevator servo without rubber grommet’s along with your pre-glued servo spacers under the servo flange raising the servo off the frame panel add one spacer on top of the servo flange as a retainer fasten using the M2 x 12mm screws. Figure 9 (Note elevator servo is interior side on the of the frame also notice servo orientation).


	Assembly of Main Shaft Bearing Blocks




		Figure 10



		Figure 12



		Figure 14




		Figure 11



		Figure 13



		Figure 15

Locate all (3) G-10 Bearing block plates, shims, and captive plates with the following hardware (12) M2 x 10mm Philips head screw, (12) M2 flat washers, (12) Press in nuts. You will also be using all (3) stock OEM main shaft bearings from your helicopter. Figure 10
Figure 11 Install (12) press in nuts (4) per Captive plate(captive plate have a flanged bearing pocket) using the same procedure noted in figure 2 install press in nuts flanged side on the flanged side of the captive plate use red thread lock when installing nuts
Figure 12 Install the appropriate sized bearing using blue thread lock into the bearing plate locate the appropriate shim and captive plate Note (shims and captive plates only differ by the size of the bearing pocket or hole)
Figure 13 assemble Bearing block assembly with (4) M2 x 10mm screws and (4) M2 flat washers and should look like assembly in Figure 14
Repeat steps for remaining 2 bearing block assemblies Figure 15


	Installing Main Shaft Bearing Blocks




		Figure 16



		Figure 18



		Figure 20



		Figure 22


	Figure 17


			Figure 19



		Figure 21




		Figure 21A


	Figure 23

Locate the left side frame panel all Main shaft bearing block assembles, Anti rotation Guide (4) M3 x 8mm button head screws, (14) M3 Nuts, and (6) original hardware main shaft bearing block screws with washers Figure 16
Figure 17 Starting with the lower bearing lock install (2) M3 Nuts with the parallel sides of the nut aligned to slide into the grove so that you have nuts installed similar to Figure 18 Note Grooves for nuts may or may not have a snug fit
Figure 19 Install lower bearing block with captive plate facing towards what would be the ground or landing skids assemble using (2) original OEM bearing block screws using Blue thread lock and tighten snug NOTE DO NOT OVER TIGHTEN These bearing block assemblies are a positive lock design by Rotorworkz they do not move or shift once screws are drawn in. Positive lock parts may have a soft or tight fit this is due to + or - .012” inch variation in G-10 thickness this is Manufactures tolerances not Rotorworkz so please pay close attention when first time installation of being block in Frame panels
Figure 20 Install remaining bearing block assemblies Repeat the above steps for middle and top bearing blocks Note All Bearing blocks should be installed with captive plates facing down towards landing skids.
Figure 21 Note the shape of the Anti rotation Guide and how it is installed into frame Figure 21A the thinner side of the guide slot will face towards the left frame side panel use OEM bearing block hardware to install guide
Figure 22 Shows installed M3 x 8mm Button head screws this allows for better clearances

Special note do not add thread lock on forward bearing block screw as later in assembly you will remove it to install a frame doubler this method is only used to seat the bearing block fully into the frame panel Figure 23


	Assemble Main Frame Parts with Motor Mount




		Figure 25


	Figure 24



				Figure 26

Figure 24 Assemble main Frame with stock OEM part to that level / stage by adding Base plate with landing skids, Battery tray and Auxiliary component tray under boom mount. (Note battery tray can be mount Vertically or Horizontal but in separate (4) hole patterns.)
Locate (2) Frame doubler plates (4) M3 x 8mm socket head cap screws (4) Original OEM aluminum washers, And motor mount. Figure 25 (Note the M3 x 8mm Screws Replace your Stock motor mount screws Due to the Frame doubler)
Remove bearing block screw noted in figure 23 in previous section
Install motor mount and frame doubler as shown in figure 26 using blue thread lock


	Installing Pitch and Aileron Servos




		Figure 27



		Figure 29




		Figure 28



		Figure 30

Locate both aileron and pitch servo (12) Servo spacers, (8) M2 x 12mm Philips head screws Figure 27
Figure 28 is optional sand the servo’s back cover plate until enough material is removed so that you hear/feel the sanding block just touching the head of the screws on servo case this allow you to gain approximately 2mm of total space to bring servo linkage balls closer to a parallel rod position if you do not wish to do this option simply add another spacer that has been provided in your kit.
Figure 29 Shows servo spacers using (2) Pre-glued spacers note the “V” shape of the spacer this is cut to allow bearing block screw clearance
Figure 30 shows servo installed using (4) M2 x 12mm Philips head screws and a spacer / retainer on top of servo flange
Repeat steps for opposite side.


	Installing and Setup of Servo Subzero Arms




		Figure 31


	Figure 32


	Figure 32A




		Figure 33




		Figure 35


		Figure 34



		Figure 36

Locate (3) Subzero arms, (9) M2 x 6mm Philips head screws, (9) M2 flat washers, (9) M2 nuts, (3) Brass servo studs. Figure 31
Figure 32 Shows (3) servo bridge plates and (3) 7mm OD flanged bearings Figure 32A shows Using Red Thread lock install (3) bearings with flanges on top. Your “S” Shaped plates should be oriented in the same position as in figure 34A this step is import so you will assemble a right and left Bridge plate

Power up your servos using you radio system remove any sub trim or mixing that may be preprogramed. Now set radio throttle/pitch to center stick your 3 cyclic servos should now be centered.

Install factory round servo wheels rotate wheels by removing an reinstalling to achieve the best 90 deg hole positions.
Using (3)M2 x 6mm screws and (3) M2 Flat washer install Subzero arms on to factory servo wheels note: wheels have 3 holes per 90 degree position you will install screws into the same hole for all three positions on the Subzero arm plate to allow for full adjustable travel
Figure 33 shows installing a 1/16” (1.5mm) Rod through both 90 Deg reference holes located in frame panels figure 36 shows location of this hole marked with a red dot.
Push your 1/16 (1.5mm) rod through the frame and through the subzero arm linkage ball mounting hole while you servo is still centered via your radio system. Now tighten all three screws enough to keep servo arm from shifting or moving. remove arm assembly and repeat for opposite side.
Figure 34 shows a small adjustable square and scrap piece of thin flat material in my case I used a scrap piece of 1.65mm Carbon Fiber this will be used to take a reference measurement of either pitch or aileron servo arms to set you elevator arm.
Figure 35 shows setting scrap material on top of the frame using a adjustable square set the blade of the square on top of a centered servo arm noting the position you rested the blade on and took measurement. Now lock blade in position use this reference
Using the preset square set your elevator servo and tight screws. Figure 36 Now.
Remove one servo arm at a time and install M2 Nuts using blue tread lock and tighten. Verify again that all 3 arms are still at there reference position adjust arms if needed.


	Installing Canopy Pins and Receiver Tray




		Figure 37




		Figure 38

Figure 37 Shows assembled canopy pins on break away tabs use (4) M2 x 6mm Philips head screws and install them in positions shown in figure 38
Figure 38 shows optional Receiver tray installed. On the frame panel note the long slots cut just above the top boom block alignment pins insert the tray as shown.
Now install stock OEM boom block and screw hardware if you are using belt driven tail you can hold this step until last


	Installing Servo Bridges




		Figure 39



		Figure 41




		Figure 40



		Figure 42

Figure 39 shows installing brass servo stud using blue thread lock. perform this step on all cyclic servos
Figure 40 shows installing Servo bridge with (2) M3 x 6mm Socket head screws not install bridge plate with the flange of the bearing is facing the servo repeat for opposite side. note: you may need to loosen all (4) servo screws to remove any binding and allow the servo to center itself perfectly inline with servo bridge bearing.
Figure 41 Shows installing elevator servo bridge with bearing facing the servo install using (2) M3 x 6mm socket head screws note you may need to again loosen all (4) servo mount screws to allow centering to the servo bridge bearing
Figure 42 shows stock frame spacer installed


	You have completed installation of you Rotorworkz HFX Conversion kit Complete any or all remainder RC component installation


		Head linkage rods

Note the below linkrod lengths are for basic setup only they may or may not be exact on your Helicopter.



	Measurements are taken between linkages shown in Figure 43 Servo to Swash 24.5mm Swash to Seesaw mixing arm 34.0mm Washout mixing arm to Flybar carrige 7.5mm Blade grip to mixing arm 2.0mm