Bell 222 ARF Electric Conversion - 2006/01

24 MODEL AVIATION
THE FULL-SCALE Bell 222 is powered by Lycoming LTS101
gas turbine engines. It has a length of 42 feet, 6 inches, and is 12
feet, 2 inches high. Sometimes referred to as the “Deuce,” the Bell
222 can be equipped with retractable landing gear or fixed skids
(utility version).
The large interior can be configured for use as anything from a
10-place utility aircraft to a six-place executive transport. With its
excellent single-engine performance, this helicopter is a terrific
candidate for offshore oil platforms or an air ambulance.
When I decided to build an electric-powered scale helicopter, I
realized there was not much of a selection in the 60 body sizes. Most
larger scale bodies are designed for nitromethane engines.
After some research on the Web I decided to go with Century
Helicopter Products’ Bell 222 ARF. This scale body is accompanied
with a great paint scheme. The model has a length of 53 inches, a
height of 11 inches, and a ready-to-fly weight of 12 pounds. I also
purchased the optional retractable landing gear.
Two design goals had to be met, one of which was obvious; the
engine-powered Bell 222 had to be converted to electric power. The
other was to design the body for easy access to the Bell’s mechanics
for routine maintenance (I’m really big on this) and repairs. The
accompanying photos help show how this conversion was
accomplished.
Choosing the helicopter mechanics was easy since I have been flying
the X-Cell line of helicopter kits from Miniature Aircraft and am
by Bob Fiorenze
A marriage of Century Helicopter
Products’ detailed fuselage and
Miniature Aircraft mechanics
This pages’s and sidebar photos by Joe Brooks
January 2006 25
Cut the Bell 222’s fuselage in half. This is necessary for easy access when removing the
battery packs for charging and the mechanics for maintenance.
Fabricate two formers from 1/8 plywood. Use
the fuselage halves as a guide and trace the
inside shape onto the plywood.
Sand the front former to conform to the front fuselage section, to
minimize the amount of glue needed. Glue it in with medium
cyanoacrylate. Glue in alignment dowels from the front side.
Drill pilot holes in the formers and keep them aligned with small
dowels. Cut out both formers at the same time.
26 MODEL AVIATION
The rear former is glued in place along with two plywood rails. The
Ion mechanics will be bolted to these rails. Note the position of the
right retract servo and plywood mounting.
Make nose-gear mount extension from plywood and carbon-fiber
(CF) tubes. All wood joints are layered with 2-ounce fiberglass cloth
and cyanoacrylate. CF tubes are wrapped with nylon fishing line and
glued with cyanoacrylate at all intersections.
Ion mechanics in stock OEM form are too tall to fit inside the fuselage. CF side frames
and aluminum channels will need to be cut down by an inch.
Trial-fit mechanics in the body. Four stock aluminum canopy standoffs will be used to
bolt nose-gear extension and landing-gear unit to main frame mechanics.
familiar with them. I decided to go with the
new electric Ion, which was designed by
Chris Stephenson of Miniature Aircraft.
Frank Noll at Futaba was helpful in
guiding me toward the best radio gear for my
conversion. The nine-channel CAH helicopter
radio with an R149 DP PCM receiver, four
9202 servos, and accompanied by the 401
gyro with digital servo seemed to be the best
combination. For the Sport Scale modeler,
this radio will get the job done and is not in
the “high-price spread” category.
Chris suggested that for my scale
application I use the Actro 24-4 outrunner
motor coupled with two 5S3P 6-amp/42-volt
Thunder Power Li-Poly batteries. This pairing
of components has the makings of an
extremely powerful system.
Flying a fast helicopter is “the best of both
worlds.” It can be flown right out of my
garage. It can hover in the driveway/back
yard, or I can fly it like an RC Aerobatics
airplane at 100 mph. The model is capable of
Loops, Rolls, Stall Turns, high-G turns, etc.
The best way to describe this helicopter’s
awesome power is for you to picture it in a 5-
foot hover, and then full power is added. The
model looks as if it is going to self-destruct
from the vertical acceleration. The flight
duration with the electric system is 14-18
minutes, depending on how hard you lean on
the throttle.
This article would be incomplete without my
mentioning the tremendous assistance from
electronic systems engineer Mickey Nowell.
As a longtime friend, he is always there to
help. MA
Bob Fiorenze
[email protected]
Sources:
Bell 222 fuselage:
Century Helicopter Products
1740-C Junction Ave.
San Jose CA 95112
(408) 451-1155
www.centuryheli.com
January 2006 27
The fabricated nose retract extension is trial-fitted to the main
graphite mechanics.
A look through the left side of the windshield. The mechanics with
the fabricated nose-wheel retract extension can be seen.
Flying this size electric helicopter can present overheated-ESC
issues. The only real solution is to run the Schulze 40-160WK ESC. It
is ideal for extended midthrottle (helicopter) use.
The rear of the fuselage with the tail-rotor transmission has been
installed. No modifications are needed in this area.
Completed helicopter mechanics with landing gear temporarily installed and ready for
test flights. Note 2.5 pounds of ballast between landing-gear skids, simulating the
weight of the body, retracts, and details that will be installed after all test flights and
radio setup are completed.
Ion-X helicopter mechanics:
Miniature Aircraft USA
31713 Long Acres Dr.
Sorrento FL 32776
(352) 383-3201
www.miniatureaircraftusa.com
Li-Poly batteries:
Thunder Power Batteries
4720 W. University Ave.
Las Vegas NV 89103
(702) 228-8883
www.thunderpower-batteries.com
Actro brushless motor:
Hobby Lobby
5614 Franklin Pike Cir.
Brentwood TN 37027
(615) 373-1444
www.hobby-lobby.com
Schulze speed control:
RC Direct
7644 Clairmont Mesa Blvd.
San Diego CA 92111
(858) 277-4531
www.rc-direct.com
More About the Machine
The excellent semiscale Century 222 (item D4033AG) is ideal
for the modeler who wants a business-class civilian aircraft to be
painted identical to an existing helicopter or decide on his or her
own fantastic paint scheme.
The completely painted fuselage is approximately $800 and is
available in two color schemes: red and black. The attention to the
design of the fuselage allows simple and easy access to main
mechanics without sacrificing scale outline.
The length of the 60-size model is 54 inches, its height is 10
inches, and its width is 16.5 inches. Expect a finished weight of
roughly 12-13 pounds with the mechanics.
The optional retractable landing gear (item CN2036RTB) was
used to enhance the realistic appearance so I could perform landings
that look world class. The retracts alone cost approximately $80 and
require a separate servo on each strut in addition to an extra on the
nose for ground steering.
The X-Cell brand of helicopters represents the perfect
combination of innovation and engineering. The Ion-X (item 1024)
is its high-performance, electric-powered helicopter that is based on
the popular Fury mechanics.
New design features include open tail-rotor gearbox and the
option for either a single- or two-stage gear-reduction system. The
available gear ratios are from 5.43 to 9.5:1
The mechanics are designed to use the low-rpm outrunner
motors or high-revving conventional motors with motor shafts that
extend at least 55mm outside the motor case. My familiarity with
the products and positive experiences are what guided me to make
the Ion my choice for this project.
At a recent air show I installed my Air Speed Indicator (see
www.rcaviation.com/fiorenze/ for details and pricing) in the Bell
222. I did three upwind and three downwind speed runs. The best
average speed was 89 mph; not bad for a helicopter! MA
—Bob Fiorenze
[email protected]

24 MODEL AVIATION
THE FULL-SCALE Bell 222 is powered by Lycoming LTS101
gas turbine engines. It has a length of 42 feet, 6 inches, and is 12
feet, 2 inches high. Sometimes referred to as the “Deuce,” the Bell
222 can be equipped with retractable landing gear or fixed skids
(utility version).
The large interior can be configured for use as anything from a
10-place utility aircraft to a six-place executive transport. With its
excellent single-engine performance, this helicopter is a terrific
candidate for offshore oil platforms or an air ambulance.
When I decided to build an electric-powered scale helicopter, I
realized there was not much of a selection in the 60 body sizes. Most
larger scale bodies are designed for nitromethane engines.
After some research on the Web I decided to go with Century
Helicopter Products’ Bell 222 ARF. This scale body is accompanied
with a great paint scheme. The model has a length of 53 inches, a
height of 11 inches, and a ready-to-fly weight of 12 pounds. I also
purchased the optional retractable landing gear.
Two design goals had to be met, one of which was obvious; the
engine-powered Bell 222 had to be converted to electric power. The
other was to design the body for easy access to the Bell’s mechanics
for routine maintenance (I’m really big on this) and repairs. The
accompanying photos help show how this conversion was
accomplished.
Choosing the helicopter mechanics was easy since I have been flying
the X-Cell line of helicopter kits from Miniature Aircraft and am
by Bob Fiorenze
A marriage of Century Helicopter
Products’ detailed fuselage and
Miniature Aircraft mechanics
This pages’s and sidebar photos by Joe Brooks
January 2006 25
Cut the Bell 222’s fuselage in half. This is necessary for easy access when removing the
battery packs for charging and the mechanics for maintenance.
Fabricate two formers from 1/8 plywood. Use
the fuselage halves as a guide and trace the
inside shape onto the plywood.
Sand the front former to conform to the front fuselage section, to
minimize the amount of glue needed. Glue it in with medium
cyanoacrylate. Glue in alignment dowels from the front side.
Drill pilot holes in the formers and keep them aligned with small
dowels. Cut out both formers at the same time.
26 MODEL AVIATION
The rear former is glued in place along with two plywood rails. The
Ion mechanics will be bolted to these rails. Note the position of the
right retract servo and plywood mounting.
Make nose-gear mount extension from plywood and carbon-fiber
(CF) tubes. All wood joints are layered with 2-ounce fiberglass cloth
and cyanoacrylate. CF tubes are wrapped with nylon fishing line and
glued with cyanoacrylate at all intersections.
Ion mechanics in stock OEM form are too tall to fit inside the fuselage. CF side frames
and aluminum channels will need to be cut down by an inch.
Trial-fit mechanics in the body. Four stock aluminum canopy standoffs will be used to
bolt nose-gear extension and landing-gear unit to main frame mechanics.
familiar with them. I decided to go with the
new electric Ion, which was designed by
Chris Stephenson of Miniature Aircraft.
Frank Noll at Futaba was helpful in
guiding me toward the best radio gear for my
conversion. The nine-channel CAH helicopter
radio with an R149 DP PCM receiver, four
9202 servos, and accompanied by the 401
gyro with digital servo seemed to be the best
combination. For the Sport Scale modeler,
this radio will get the job done and is not in
the “high-price spread” category.
Chris suggested that for my scale
application I use the Actro 24-4 outrunner
motor coupled with two 5S3P 6-amp/42-volt
Thunder Power Li-Poly batteries. This pairing
of components has the makings of an
extremely powerful system.
Flying a fast helicopter is “the best of both
worlds.” It can be flown right out of my
garage. It can hover in the driveway/back
yard, or I can fly it like an RC Aerobatics
airplane at 100 mph. The model is capable of
Loops, Rolls, Stall Turns, high-G turns, etc.
The best way to describe this helicopter’s
awesome power is for you to picture it in a 5-
foot hover, and then full power is added. The
model looks as if it is going to self-destruct
from the vertical acceleration. The flight
duration with the electric system is 14-18
minutes, depending on how hard you lean on
the throttle.
This article would be incomplete without my
mentioning the tremendous assistance from
electronic systems engineer Mickey Nowell.
As a longtime friend, he is always there to
help. MA
Bob Fiorenze
[email protected]
Sources:
Bell 222 fuselage:
Century Helicopter Products
1740-C Junction Ave.
San Jose CA 95112
(408) 451-1155
www.centuryheli.com
January 2006 27
The fabricated nose retract extension is trial-fitted to the main
graphite mechanics.
A look through the left side of the windshield. The mechanics with
the fabricated nose-wheel retract extension can be seen.
Flying this size electric helicopter can present overheated-ESC
issues. The only real solution is to run the Schulze 40-160WK ESC. It
is ideal for extended midthrottle (helicopter) use.
The rear of the fuselage with the tail-rotor transmission has been
installed. No modifications are needed in this area.
Completed helicopter mechanics with landing gear temporarily installed and ready for
test flights. Note 2.5 pounds of ballast between landing-gear skids, simulating the
weight of the body, retracts, and details that will be installed after all test flights and
radio setup are completed.
Ion-X helicopter mechanics:
Miniature Aircraft USA
31713 Long Acres Dr.
Sorrento FL 32776
(352) 383-3201
www.miniatureaircraftusa.com
Li-Poly batteries:
Thunder Power Batteries
4720 W. University Ave.
Las Vegas NV 89103
(702) 228-8883
www.thunderpower-batteries.com
Actro brushless motor:
Hobby Lobby
5614 Franklin Pike Cir.
Brentwood TN 37027
(615) 373-1444
www.hobby-lobby.com
Schulze speed control:
RC Direct
7644 Clairmont Mesa Blvd.
San Diego CA 92111
(858) 277-4531
www.rc-direct.com
More About the Machine
The excellent semiscale Century 222 (item D4033AG) is ideal
for the modeler who wants a business-class civilian aircraft to be
painted identical to an existing helicopter or decide on his or her
own fantastic paint scheme.
The completely painted fuselage is approximately $800 and is
available in two color schemes: red and black. The attention to the
design of the fuselage allows simple and easy access to main
mechanics without sacrificing scale outline.
The length of the 60-size model is 54 inches, its height is 10
inches, and its width is 16.5 inches. Expect a finished weight of
roughly 12-13 pounds with the mechanics.
The optional retractable landing gear (item CN2036RTB) was
used to enhance the realistic appearance so I could perform landings
that look world class. The retracts alone cost approximately $80 and
require a separate servo on each strut in addition to an extra on the
nose for ground steering.
The X-Cell brand of helicopters represents the perfect
combination of innovation and engineering. The Ion-X (item 1024)
is its high-performance, electric-powered helicopter that is based on
the popular Fury mechanics.
New design features include open tail-rotor gearbox and the
option for either a single- or two-stage gear-reduction system. The
available gear ratios are from 5.43 to 9.5:1
The mechanics are designed to use the low-rpm outrunner
motors or high-revving conventional motors with motor shafts that
extend at least 55mm outside the motor case. My familiarity with
the products and positive experiences are what guided me to make
the Ion my choice for this project.
At a recent air show I installed my Air Speed Indicator (see
www.rcaviation.com/fiorenze/ for details and pricing) in the Bell
222. I did three upwind and three downwind speed runs. The best
average speed was 89 mph; not bad for a helicopter! MA
—Bob Fiorenze
[email protected]