Millennium

Robbe / Schlüter Millennium

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[mikesmillie]

Interspersed are pictures of my Millenium 1.5 (not quite 2). It has a Futura Canopy on it because I think it looks better. Avionics are Futaba PCM receiver, Hunter Alpine base antenna, 9202 cyclic and pitch servos. JR 1400 battery, BC-6 glitch counter and Ultimate Switch. Futaba 9250 on the tail and a HS525 on throttle. Gyro is a Futaba 501, Governer the Futaba GV-1. Mainblades are 700mm Gamma and tails are 105mm NHPs. Flybar paddles are empty weight MinAir ProIIs with flybar weights halfway out. Power provided by a OS61SXWC with Enya 3 plug blowing 15% Coolpower/PowerMaster smoke into the Curtis Muscle Pipe. Carbon H and V fins, carbon boom supports with KSJ brace and carbon tail control rod. Purple finish washers, Hayes 2oz header tank and Uniflow tank setup.

Stage 1- Fuel Tank

Do not use the felt washers when installing the nipples. A plain washer and Goop is preferred.
Uniflow tank plumbing is easily installed at this time. A additional passthru nipple is required for the additional clunkline.
Ensure the tank cap S2562 is tight after cleaning the fuel tank of contaminants.

Stage 1.2 - Fitting the Rear Frames

The fuel tank is a tight fit in the frames and will wear away. Thin servo tape or packing tape will provide some protection.
Use washers under the bolts S0030.
Do not overtorque the bolts S0030.

Stage 1.3 - Fitting the Front Frames

Add washers to all bolts.
Wings S4670 are optional but since the Millie is a bit tailheavy worthwhile to install.
Aluminum bulkheads S4820 are available.

Stage 1.4 - Bellcranks and Top Frames

Use a dap of medium CA when installing the S3495 balls.
Lube bearings S4035
Don't forget the two washers S4029 between the bearings S4035 in the bellcranks.
The bellcranks go into the top frame holes in the following manner:

Add washers to all bolts
Do not tighten the three S3037 bolts since the tailboom has to slide into the holder in Step 7.

Stage 1.5 - Fitting the Main Side Frames

Add washers to all bolts
Do not overtorque the canopy standoffs S4835. Use loctite.

Stage 2.0 / 2.1 /2.2 - Gearbox

Don't forget to loctite S3467 and S0073 screws.
Use light teflon oil to lubricate the freewheel S4448. Do NOT use grease.
Make sure the freewheel one-way bearing is installed the right way iaw the illustration.

Stage 2.3 - Main Rotor Train

Clean and polish mainshaft with oil and 600 grit sandpaper.
Loctite mainshaft into bottom mainshaft bearing.
Do NOT substitute for lower Jesus Bolt S3522. This must be a shouldered, hardened bolt.
Do not overtorque bolt S3522. This will distort the aluminum and bind up the freewheel bearing.

Stage 3.0 - Tail Rotor Take Off

Lube bearings S4605
Loctite shaft S4304 into bearings.
Loctite S4742 and S0077 setscrew. Ensure the setscrew engages the flat on shaft S4304.

Stage 3.1 / 3.2- Fitting Dome Bearing & Tail Rotor Takeoff

Add washers under all bolts.
Loctite bearing S4667 to mainshaft S4648
Optionally install a Bergen hollow mainshaft to save weight.
The tailrotor power take-off gear MUST be placed on the crown gear without any gap and with zero backlash.

Stage 3.3 / 3.4 - Swashplate install

Lube the swashplate S2972 with light teflon oil.
Ensure the swashplate slides freely on the mainshaft. If not, polish the mainshaft with oil and 600 grit sandpaper.
Add washers to bolt S3037.

Stage 3.5 - Lower Angle Brackets

Add washers to all bolts.
Optionally install the CF angle brackets
S4837 spacer can be replaced with the optional plastic lower support.
A carbon fiber lower L bracket S4818CF is available.

Stage 3.6 - Servo Mounts

Lube bearings S4035

Do not overtorque bolts S3074. Servo cradles must be able to move without any resistance.
The optional collective push-pull conversion is shown in the picture.

Stage 3.7- Landing Gear

Add washers to all bolts.
Glue in end caps S3146 or they will be gone after the first flight.
A M4 bolt and nut goes in the back center of the struts if the optional plastic lower support is installed.
If the optional M4 bolt is used, ensure it does not puncture the fuel tank. The new soft tank will expand with muffler pressure, especially if a YS engine is used. Some hard material glued to the bottom of the tank will prevent penetration.
The yellow Millennium 2 landing gear struts S2800 are shown. A tougher choice are Robbe's black struts or MinAir Tuff struts.

Stage 4.0 - Collective Pitch Compensator

Lube bearings S4035.
Do not forget to install two washers between the S4035 bearings.
Use a dap of medium CA when screwing balls S3495 into the arms S4626.
Loctite bolts S3198 into pitch compensator S1025.
Ensure mixing base slides smoothly on mainshaft.
Optionally trim the brass slider on S4665 level with the plastic part.
Ball links should not be tight fitting to the swashplate balls.

Stage 5.0 / 5.1 - Main Rotor Head

Lube bearings S0212, S4287, S4645 and S0364
Grease thrustbearing S1551
MAKE SURE the thrustbearing race with the bigger inner diameter S 1551 goes on the axle S4542 first. The smaller ID race goes on the outside towards the blade grip
Lube the O rings S3506 with a non petroleum oil (cooking oil).
Before bolting on the blade grips S3534 make sure the arms are on the correct side of the main rotor hub S4646.
Added shims S4205 with increase the dampening. Soft dampening for sport and FAI flight, hard for 3D.
Optionally install the upgraded Millennium II head dampening kit with four O rings.

Stage 5.2 / 5.3 - Mixing Levers and Flybar

Lube the bearings S4035.
DO NOT substitute for upper Jesus Bolt S3522. This must be a shouldered, hardened bolt.
The big ball links S3536 or S4256 must be installed before the flybar paddles or weights.
S4256 is used when hovering at center stick. Use the S1293, S3510 and S3536 combination for zero degrees pitch at center stick.
Center the flybar as close as possible. Length variation should not exceed 0.5 mm.
CA balls S3495 into mixing arms S4632
S3469 collar may be very tight on the guide pins from the Collective Pitch Compensator. Use a file or similar to carefully increase the slot for a slightly loose fit of the pins.
Optional Flybar paddles are MinAirs Pro II, KSJ Purple from the Millennium II or any of aftermarket sets available.
Use medium CA when screwing on the flybar paddles.
Make sure the flybar paddles face the correct direction before the CA hardens.
Disconnect the linkages to the flybar and use the flybar weights S1587 to balance the flybar and paddles.

Stage 5.4 - Main Rotor Head Install

Head button S2868 comes with self tapping sheet metal screws for plastic heads. Use M3 bolts and loctite to install the button on the metal Millennium head.
Do NOT substitute for main blade bolts S0047. These are special, shouldered and hardened bolts. Loss of a blade in flight will result in total loss of the helicopter and may cause serious injury or death.

Stage 6.0 / 6.1 - Tail Rotor Gearbox

Lube the bearings S4303 and S4833.
Ensure the setscrews S0041 engage the flats on the input and output shafts S4747 and S4628.
Loctite the bearings to the shafts.
Adjust the spacer S4679 to eliminate any play on the output shaft S4628.
Fill the entire gearbox with teflon grease.

Additional security for the tailpitch control arm S4627 is provided when installing a longer bolt for S0031 and adding a M3 nut and washer on top of the S4624 gearcase.
Ensure the ball links on the tail pitch slider pivot freely.

Stage 6.3 - Tail Rotor Hub

Lube the bearings S3367.
Grease the thrust bearings S3364.
Like in the main rotor hub, the thrust bearing race with the larger ID goes on first, the smaller ID race goes towards the blades.
CA the balls S3400 into the blade holders S4631.
Balance the entire assembly with a High Point balancer.

Stage 7.0 / 7.1 /7.2 - Tail boom and Torque Tube

The boom end with the two holes goes toward the back.
The sleeves S4664 can also be glued with medium CA to the shaft S4753.
The new shafts do not have the holes at the bearing locations which eliminates the potential weak spots.
CAUTION - the bearing holders S4664 may wobble a bit and eventually damage the inside of the tailboom. In extreme cases this may cut the tailboom in half. Inspect at regular intervals. Upgraded, metal bearing holders are available.
The upgrade kit S1076 eliminates the S4664 bearing holders with a O ring dampened aluminum insert. This is a recommended upgrade if the original setup needs replacement.
Different colored booms are shown.

Stage 7.3 - Tail Boom Stabilizers

The tailrotor gearbox has a crush resistant metal housing but Vertical fin bolts S0035 should not be overtorqued. Ensure the tailrotor gears do not bind after tightening the bolts.
It is important that the horizontal fin S4642 is held securely to the boom. Any looseness will negatively affect the tail rotor gyro gain. It may be necessary to use electrical tape around the boom for a tight fit.
The boom supports S4842, if installed at the illustrated position on the frame will rub against the fuel tank. Installing washer will space out the supports.
Alternatively, install the boom supports S4842 at the lower location of the frame using the bolts going into the aft plastic landing gear spacer. This also requires washers to clear the fueltank.
Aftermarket CF boom supports are available and work fine. A KSJ boom support brace is recommended to prevent resonant vibrations in the thinner CF rods.
Millennium 2 fins now come in bright yellow. Carbon fiber cut out fins are also available.

Stage 8.0 / 8.1/ 8.2 - Engine bearing block and clutch bell

Lube the bearings in S4822.
The bearing block S4822 and the 13 tooth pinion gear S4803 are replaced by Sxxxx and Sxxxx respectively if the Millennium 2 start system is installed.
When installing S4822 bearing block, ensure the ball is facing forward left.
Make sure the large bearing in clutch bell S4826 is tight. Use loctite if loose.
Loctite the 13 tooth pinion gear S4803 into the bearing in S4822.
Loctite the start shaft S4830 into the top bearing in S4822. Don't forget the washer S4816. A glowplug washer may be substituted.
There should be no vertical play in the startshaft once the hex coupler S4832 is fastened to the shaft. The shaft must not be so tight as to preload the top bearing in S4822.
Make sure the setscrew in the hex adapter S4832 engages the flat in the start shaft S4830.

Stage 8.4 - Engine

The kit comes with hardware S4150 to install engines with special crankshafts. These are usually identified with a 'G' in the part number i.e. OS61SXHG.
To install an OS61 adapter nut PN-xxxx and collet, for a YS61STH the adapter PN is xxxxx, collet PNxxx. S4150 is not used in this case.
Dial indicate top of the one way start adapter S4829 to minimize high frequency vibrations.
Lube the oneway bearing in S4829 with thin oil. Do not use grease.
The start system from the Millennium 2 kit may be installed instead.
Here is a list of required parts to change to the M2 start system:
S0019 M3x5 bolts
S0500 O Rings
S4651 Hex Adaptor
S4805 Spacer
S4806 Top Hat
S48031 13 tooth gear *
S48221 Bearing Block *
Note that the plastic hex guide in the new bearing block is too small to allow a 6mm start shaft to slip through. Use a dremel to open it up before installation in the heli.
*** You can save some Bucks and reuse the old bearing block by removing the top bearing and inserting a S4804 Hex guide. Also if you have a lathe, remove 1mm from the inside of the old 13 tooth gear to allow the start shaft to fit.

Stage 8.5 - Engine mount

Leave 1/2mm vertical play between the clutchbell and fan to prevent binding to due thermal expansion.
When aligning the engine ensure the startshaft is freely rotating and the pinion to maingear mesh has no binding.

Stage 9.7 - Tail rotor linkage

The linkage must be totally friction free to prevent load on the tailrotor servo and to maximise gyro gain.
The tailrotor control rod guides S4644 should not be exactly evenly spaced to prevent harmonic vibrations of the rod.
Optionally install a carbon fiber control rod.

Stage 10 - Fan housing

The fan shroud supports S4604 will crack from engine vibrations. Carbon fiber upgrades S4604G should be installed when convenient.
Alternatively a fiberglass fanshroud can be installed.
The Millennium 2 canopy comes in bright yellow. Fiberglass canopies are also available.

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