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Old Aug 28, 2007, 01:00 PM
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Build Log

Ion-X to X2 Conversion Log


Hello guys,

As some of you know I am working on converting my Ion-X to the new X2 version. I will use this thread to log my progress, experience and test flights.

Here are the main reasons I chose to convert the Ion:

1) To eliminate the secondary gear which in my case wore out fairly rapidly.
2) To be able to fit (under canopy) larger capacity TP 5000mAh packs for increased power, flight time and performance.
3) To have the option of going 12S down the road with an Actro motor and belt drive.

MA sent me the beef'd up double main gear which handles the higher voltage setups. I will however keep it at 10S for now. The gear ratio I chose was 20.05:1 which is very close to my current 20:1 ratio. I'm expecting a strong performance increase just by being able to fit the stronger 5000 TP cells. Later on I am planning on at least going 11S and maybe trying a flybarless setup.

Feel free to post comments or suggestions as I go along with the build thread.

Chachin..
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Old Aug 28, 2007, 01:16 PM
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Conversion Kit


Here is the conversion kit as it arrived out of the box.

The kit is contained in four bags. In general, the conversion kit includes the new main frame and attach hardware, the motor mount, main gear, the belt, pulleys, battery velcro and some servo linkages.

The manual was sent via an e-mail link which opened up a PDF file that I could print. It consists of a photographic documentation of an Ion-X2 kit built from scratch with assembly notes. It is much smaller (quicker to go through) than the original X1 assembly manual.

Chachin..
Old Aug 28, 2007, 01:24 PM
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Before Pics


Here are the official before pictures of the Ion.

Chachin..
Old Aug 28, 2007, 01:37 PM
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Disassembly begins


Of course, the conversion begins by stripping down and disassembling the main frame of the X1. It is essentially a kit re-build with the exception of the rotor head and tail section.

I began by removing the main blades and the battery mounting plates for ease of access. I then proceeded to remove ALL electronics from the heli.

Too bad I have to go to work now . More to come tomorrow as I continue to remove the head, tail and take apart the frame.

Chachin..
Old Aug 28, 2007, 05:28 PM
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Chachin,

Thanks for this thread. I'll be looking to do the same conversion with my DS Neu setup later this year. What gears and pulleys did you get from MA for the 20.05 ratio? Tooth numbers on double main, main pinion, pulley, and motor pulley/pinion. Thanks mate.

Cheers,
Tom C
Old Aug 29, 2007, 01:30 AM
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Hello Tom, here are the tooth counts:

> Double Main Gear = 93t
> Pinion gear = 12t
> Idler shaft pulley = 44t
> Motor pulley = 17t

All numbers were double checked. This actually gives a gear ratio closer to 20.06:1 (the number is 20.588...). I would be very interested in your experience with the X2 upgrade as well . I may try an 11S setup with the Neumotor. We'll see.

Got the rotor head, main gear and tail boom removed from the frame.

Chachin..
Old Aug 29, 2007, 01:33 AM
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Looking good, i am surprised at how big a job this is.

Please keep the thread updated so we can all follow the ride.
Old Aug 29, 2007, 01:36 PM
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Yeah it's pretty much a re-build... hehe. Having to change out the frames is what makes it so much work. I will keep the thread updated.

Got the landing gear, secondary gear assembly, rear U-channel, tail boom holder case and fwd/aft bearing blocks removed.

I should have more time available to work on it tomorrow. I'm very close to beginning the actual assembly .

Chachin..
Old Aug 29, 2007, 02:03 PM
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Looking good. I am running my first X2 conversion with a 1521 1.5 on 12s with a 19.33:1 ratio. It is a very hot setup! You guys will love the X2.
Old Aug 30, 2007, 02:20 AM
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Wow mudbogger, that must be an insane setup there . Is the belt holding up well on 12S?

Well I finished tearing down the X1 frame. Man, got it down to the nuts and bolts... hehe. I removed the fwd U-channel, bellcranks, canopy studs, fwd LG mount, swashplate guide, and frame spacers. From here on out it should be all assembly.

I thought it would be interesting to do a side by side comparison of the new X2 vs the X1 side frames. The most noticeable difference is the added space up front to mount the batteries, other than that they look very similar. The other major difference should be noticeable later on when the pulley system and motor mount are installed.

Chachin..
Old Aug 30, 2007, 02:27 AM
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Ion-X2 Conversion Kit


Thought I would post a better pic of the conversion kit before proceeding. Here is everything that was included in my kit.

Chachin..
Old Aug 30, 2007, 10:28 AM
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The 12s Neu is a very hot setup indeed. 1950 rpm at 65% throttle on the powerjazz.
Belt looks like new with about 50 flights so far.
Old Aug 30, 2007, 01:04 PM
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X2 Assembly begins


Good to hear that Jon. I feel confident I will be able to transition my heli to HV down the road . Thanks for letting me know I'm missing the lower battery channel. I will contact MA. It shouldn't really interfere much with the assembly process.

All right time to get started with the assembly of the X2 .

The instruction manual starts you off by putting together the left frame. First thing to do is bolt on three of the frame spacers and the left bellcrank stud.

Chachin..
Old Aug 30, 2007, 01:32 PM
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Rear channel


Up next is the vertical rear channel. The X2 channel now uses captive nuts at all 8 bolt holes. The X1 channel only has 2 installed at the top. MA provides captive nuts in the conversion kit for installation.

Per Jon's (mudbogger) recommendation I used an 11/64 drill bit to enlarge the 6 lowest holes of the rear channel. I used the pliers shown in the picture to insert them. Had to use my body weight to press them in. A larger set of pliers is recommended.

Chachin..
Old Aug 30, 2007, 01:39 PM
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Installed rear channel and lower bearing block.

Note: slightly corroded bolt heads will be cleaned after torquing.

Chachin..


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