Mon 17 May 2010
MD500 Restoration – Week Three
Posted by Flyboy under Flight Stuff , From the World of Richard , MD500e Restoration Project[2] Comments
MD500 Tear Down
We are now into week three of my MD500 restoration project with my friend over at Phoenix Heliparts and the 500 is looking less and less like a helicopter and more and more like some type of model or kit. It does not even resemble anything close to a helicopter, or something that was flying through the air mere weeks before! But yet it is – and the project is moving forward.
In any type of undertaking of this magnitude, you really have to keep the end result in mind. Watching the progression from flying machine to a stack of parts is like watching your kid go off to camp without you! A necessary step in life, part of a growing process, but not real fun (for you). I am quite certain the helicopter loves the attention it is getting – I just want it back already! However, I realize that in the end, this machine, my machine - will be far more than the sum of it parts and for that reason, this project is worth the wait!
Front View of 500 during Tear Down
So as you can see, the entire front of the helicopter has been removed. One of the big changes is the removal of the “church windows” on the 500 that were present on my year model. “Church Windows” identify the design style where there are eight lower windows as opposed to two lower windows. (see below). This removes a visual obstruction from the pilot’s view and (in my opinion) give the 500 a much cleaner look.
500 w/Church Windows
500 W/No Church Windows
As a result of the modification, the cross members supporting the windows as well as the supporting parts of the window “frame” coming from right by the main cabin doors. This opens up a lot of visibility to the pilot (and the co-pilot) but requires the removal of the “excess” parts and the installation of all brand new windows from Tech Tools. Overall both an aesthetic and practical improvement of the ship. My 500 needed all new front glass anyway so this was just a step in that general direction.
Moving on, we can see that they are working on cleaning up all of the engine compartment. The engine is out, almost all of the wiring is out and the technician is working on cleaning up the engine bay so it can be detailed and repainted before getting put back together (eventually). Its important to note the level to which the 500 has been torn down in just a few short weeks. While there are some controls still in place, almost the entire ship has been disassembled with more disassemble to come.
Cleaning up the engine compartment
After the engine compartment was cleaned up and ready for paint and other repairs, it was time to turn the ship on its side and get ready to do the sheet metal work on the bottom of the ship. In its previous life, some antenna installations and marginal metal work lead me to the decision to replace half of the skin that covers the belly of the helicopter. In order to do that (easily), the ship is placed into a special jig and then rolled over onto its side where it is far easier for the sheet metal folks to do their job.
500 on its side
Looking Broken
So whats next you ask? Well after all of the sheet metal repairs have been completed, then the 500 will get stripped of all of its original paint and get ready for even further work. The project is moving along quickly and there has been a lot done, but still much more to go as we move forward. Please stay tuned and check back every week or so for a new update!
Hi – I am the author – Richard Sears. I have been a pilot and flight instructor for over 20 years!
If you live in the San Diego area and would like to arrange a free airplane or helicopter flight for your child (age 8 to 18) through the EAA Young Eagles program please email me at richard@sears.net
If you are a Scout Master, I can work with your troop on the Aviation Merit Badge and provide all ground training and flights necessary to meet the latest requirements of the Aviation Merit Badge. I am a registered Merit Badge Counselor with the BSA San Diego – Imperial Council.
All my flight time is donated, there is no cost to the parents or the troop.
Parents are always welcome to ride along and get hooked!
May 20th, 2010 at 20:20
The 500 is looking great, Richard! I’d love to see it when it’s finished.
May 24th, 2010 at 15:01
Thanks Rob – I will continue to post pictures here until its completed, then fly it up to see you!