Esmart build (Working It Out) Pictures and video

Since My E-smart has been nothing but a thorn in my side I have decided
to tear it down completely and rebuild it piece by piece.

During teardown I found some loose screws on the bearing blocks and
discovered the frame was out of square and crooked.

Also the last flight I had with the rough landing that broke the vertical
fin I have traced it to a malfunctioning ESC.

So I have in the last few days spent over $300 in new parts for this
E-smart and thought I would post the rebuild pictures.

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Trex 600 3D solid CF verical fin.
95MM CF tail fins
CNC horizontal fin mount (swift)
CF boom supports (swift)
New boom (swift)

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Align DS620 servo.

Also was thinking about new battery mount. What do you guys think???

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I have a lot more to do and will post the re-assy. of the ES600...
All new servos coming, ESC, and batterys...

You should have some great tail authority with those blades.
As for the battery tray, I seen a post either on RCG or Helifreak were someone had ordered another frame bottom and put that in place of the top tray. The canopy is so large that I don't think there was any interferance and because it is much longer than the top tray, it worked out very well. I think they mounted it horizontal and layed the pack on top instead of on an angle. Helidirect sells frame parts and is very fast with shipping as well.

Love the pics and especially the info about the tail blades and fin

I attached a piece of flat aluminum to the top shelf and it projects 3 7/8" out in front of the top shelf. Velcro on that and on my 5S batt and I have perfect COG with that batt mount set up.

Donnie D

By the way, it may be my eyes or an optical illusion, but it appears your skids are on backward.

Yea!!!DD those skids are in fact on backward!! Pretty sharp eyes for an old guy!!!

I knew I was good for something FD. I can't fly worth a toot.

Donnie D

Hey Guys,

Yes the skids are on backwards, But if you look at Justin Chi's
Fleet he runs his skids that way.

I thought I would try it. Kind of looks sleekish.

Also With the battery I was going for the angle effect as it works well
for the EXI and trex heli's.

The plan was to just drill a hole and install some screws and nuts. Velcro
the battery down and mounting the ESC underneath.

I am wondering how the stability is effected when either placing the battery
on the top, at an angle or on the bottom shelf.

The way I show it would cost nothing but the time to drill 2 holes, and if
it works could be a great modification.

Let me know if putting the skids on backward makes you fly like Justin Chi, and I'll change mine around too.

Donnie D

WOW I didnt think of that....

Man I dont know if I will ever fly like that kid!!

He is good! I loved the corn killing video....

I don'y quite understand what the problem with battery placement is!!! I use 6S/5000 and it fits in the bottom try swell!! Just need to keep it away from the main shaft nut!!!
I think Nuttsey uses a 5S and also puts it there with no problem..

I use 6S and it sticks out the front of the tray 4 1/2".

I use aluminium angle srips but dont like it. So if I angle the battery might
be more secure ,neat , and balance the heli better.

I am psting the picture of the backwards skids....

Here it is. Stupid? or cool?

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I really don't want to call it stupid but I don't think its very cool myself, but thats the thing.. to each his own!!! I'd like to see a pix of your battery that hangs out 4.5 inches!!

I like it with the skids going the normal way, but thats just me, but I prefer to keep my battery underneath, I've had a few very intense crashes with my E-Smart and having it 3/4 encased in a aluminum cage has helped to keep my batteries from getting damaged.

Here is the original battery photo shows it hanging out the front of the heli...


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As you can see I dont have any protection and thats why I have been considering
changing the upper piece and by putting it at an angle it wont stick out so far. Thats the plan.

I would love to see other esmarts but nobody seems to post mechanical pictures
only the pretty ones...

Dont know about the skids you guys might be right...

Yup thats just what mine looks like... I think thats the best placement for the battery... As nuttsey said it is 3/4 enclosed. I've had a couple really hard crashes with mine too with no damage to the battery. I think the skids look best the right way! I've been using the Align 600 nitro pro 3D skids!! They are way cool.. 230mm wide and low lookin.. gives it a mean sorta stance!!

Fatdaddy, What kind of bracket system did you manufacture for the battery?
I find it really hard to get the batt. to be really solid and without fear of
tossing it and the mount I made while doing hard manuvers.

I plan on tossing this heli around when it flies good. I need a really solid
mount that wont cost me any money$.

Wife says I am done with the $$$$ for awhile....

So What? Your done with the wife for awhile!!? That will leave lots of time for helis!!
I didn't do anything, I use a zip tie inside the lower frame to keep the battery from touching the main shaft. Also I use this 3M stuff, I think its called double lock.. Its like velcro sorta but plastic. Then I use a small bungee cord around the front of the batt. and the frame, Nutts uses rubber bands!! So for yours I say push the batt. further back inside the frame till just before it would touch the main.

FD, It doesnt sound like yours is like mine at all. I would love to see it.
My batt. sits on the frame of the heli only 1 inch. Thats not enough
to do anything. If I moved it back you know this would throw off
the CG really bad. Look at my ptcture again. You will see everything
is mounted to the front and thats the only way I could balance the CG.

I used two 3 inch pieces of angle thats mounted to the front skid screws.

Can't really see the angle you mention. I don't think the balance issue makes much diff. with a heli this size. With my batt. pushed back to the main, it hovers with pretty much hands off the sticks. Now don't all you jump me , you know what I mean. you don't need much if any imput in hover to keep it in place. Mine is the CF but I still don't think it matters much about balance.. This heli balances its self!! All my stuff is mounted up front too except I use a REC. battery and thats in back down bottom.
I've had a computer crash awhile ago so I will have to take some pix and try to get them up.. I'll go to photobucket and see if there are any to put up..

wow, my batter sits almost 2 inches back, it stops right before the main shaft

Nuttcaze, Do you balance your CG?

I have never heard of someone not checking and balancing the heli's CG
untill FD mentioned it.

BY the way on the picture that shows the batt in the frame, the velcro you
see around the center of the battery is going around the L shaped brackets
that are atached to the skid screws.

Now I didn't say I don't check to see where the CG is. I just don't think it is that important on the larger helis.. And I don't think Nuttsey checks his at all if I recall what he told me.. I believe my "E" is balanced pretty well even with the battery back as Nutts says his also is, buy I also use the REC pack and that goes in the back so I think that helps too.

I really like the battery mounted in this position. Very strong and very easy
to get too. I used a rubber o-ring that goes from 1 front canopy mount
to the other. Ofcoarse I used velcro under it. Sound like I will be a pioneer
on this way of mounting the battery.

Lots of succesfull helis use this position of mounting the battery so
why not the esmart. It looks like my EXI 450...


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And a trex 600...




I am waiting for new cyclic servos to show up and a new ESC. Then we can balance
the CG and see where everything sits. Then ofcoarse will be the video of it fly'n.

I'm gonna fly the blades off my fleet today!!!! I will take some pix as I go thur them and get them up as I can!!! Nobody here to shoot vid. but I'll get some somehow soon..!!
Your battery mount looks good to me. I'll make sure I get a good shot of mine, I'll also check CG just to see.

CG - whats that, lol, yeah I stopped worrying about the CG of my helis a long time ago I just go fly

Everything is coming together good. Just installed the new HS-6635HB cyclic
servos. The gear mesh has been set. the entire frame was torn down and
re-assembled to be square and blue locktight on the screws.

You will notice I have the new Turnigy 5000 6S battery mounted. So far the
CG looks good with this battery put there.

I was going to post updated pictures but the insert url button is gone.....

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Ok here are some pix of my "E" battery set up!!

Thanks FD, Cool pictures I liked looking at them.

How did you get the trex mounts to fit on your boom
for your rudder servo?

I have those too, but havnt put them on because they
need a spacer to fit .

Your battery looks like it fits good in there...

The servo mounts are from CNChelicopter.com and I simply used a belt sander on evch half and took off enough to close the hole up to size. I also used a bit of foamy tape as a cushion.