Our aim is to take this helicopter back to its former glory days, and eventually return it to its playground in the air, so that it can be used for historical and airshows around the country.
READ THE BLOGWe are delighted with the progress in 2019, and we are hugely excited by the prospects of 2020. You are invited to join us on our journey, and hope you enjoy the ride.
READ THE BLOGIn December and early January there has been continued work on the helicopters electrical parts and wiring. We have now connected power to the aircraft. And are in the process of working through the electrical systems checking the AC and DC power after re wiring some systems.
READ THE BLOGOur team at Weald Aviation have been working very hard on our Lynx in recent weeks.
There has been a lot of work going on behind the scenes, as testing and inspections are on-going on the installed systems of the helicopter. Testing is an essential part of the re-development of the Lynx, and we are grateful of the expertise of Weald Aviations team.
Our Lynx has had plenty of attention recently, with lots of work undertaken recently by Weald Aviation.
This week she has had a new hydraulic return pipe fitted to her tail boom, had her No.1 hydraulic system cleaned, the main rotor gear box removed and area cleaned, her tail rotor gearbox removed and had all of her NDT zones marked up.
A pretty significant piece of work, which takes time and expertise, and we are greatful we have a team with such knowledge looking after her.
• MOD 0821 fuel pipe fit completed
• Tail rotor gearbox fit started
• Intermediate tail rotor gearbox fitted
• Intermediate gearbox cooling fan installed
• Torque adaptor for IGB fan made
• Pilots seats inspected for serviceability and missing parts
• Hydraulic reservoirs refitted – pipe work refit started
• MRGB oil coolers removed and packed up to be sent away for overhaul.
READ THE BLOG• ADC filter fitted
• Starter generator cabling inspected and continuity checks carried out
• Rotor head packed for transport
• New rotor head removed from aircraft and delivered to north weald
• No.5 driveshaft MOD states research carried out and AGS required
• Tooling required for rotor head overhaul located
• ECU inspections completed
• ECU MOD state research carried out
• MRGB oil cooler test box switch repaired
READ THE BLOG• No.1 engine bay stripped and cleaned, inspections started
• No.2 engine bay stripped and cleaned, new speed tape fitted and inspections started
• ECU and ECU bay MOD states researched to bring to correct level
• Fire extinguisher pipes removed, flushed and refitted
• No.5 tail rotor drive shaft trial fitted
• Extensive research into how to refit all drive shafts carried out and plan changed – MRGB will now be fitted first and adjustments to shims on all drive shafts made
• MRGB started to be dressed with all required components
• No.1 engine bay fitted with new aluminium tape and sealed with RTV – components have begun to be refitted, still on going
• No.2 engine fitted with new aluminium tape and all available components have been refitted – waiting on a bracket to support a cabin hot air take off valve – still on going
• ECU and ECU bay inspections have been carried out, the MOD state has been determined and the missing component required has been ordered.
• Forward fuel tank pump has been wired up correctly and repaired after being found damaged during checks for continuity
• All fuel tanks have been cleaned and hovered again after previous work to ensure no FOD.
READ THE BLOG• Both collector and forward fuel tanks have been tested for leaks.
• Several leaks have been fixed in various tanks – one drain replaced, one fuel pump replaced – awaiting another fuel pump to make one complete pump.
• Cut wires within fuel pump have been repaired
• X3 tanks approx. 1/3 full – more leaks may present themselves as the tanks swell due to the fuel and more fuel is added.
• Bracket for MOD0821 manufactured and fitted to fuel pipe – awaiting Pclip.
• MRGB continued to be dressed – x2 servos now fitted and x2 control lay shafts slaved into place – awaiting O-rings to fit hydraulic pipes.
READ THE BLOG• Fuel leak started over the weekend, has been traced to the forward bag tank.
• Collector tanks have been filled completely and sealed. Waiting to see if any leaks occur over the weekend
• P-clip fitted to MOD fuel pipe and bracket from last week.
• Sump panel from forward fuel tank removed for seals to be checked to try and locate leak
• Cabin hot air valve fitted to port ECU bay and secured. Once fireproof P seal arrives and is fitted ECU bays will be ready to receive engines.
• MRGB continued to be dressed – All servos fitted to new MRGB. Serviceability inspections have been started. Light corrosion found on No.1 engine drive coupling, corrosion removed and treated.
READ THE BLOG• Forward tank defueled and sump panel removed to inspect seal for damage, none found so panel refitted and tank filled with fuel.
• Forward tank still leaking so defueled and tank removed from aircraft.
• Tank inflated with low-pressure air and x3 leaks found.
• Collector tanks completely filled and main tanks filled a few inches.
• Another leak has appeared but unclear if it is residue from previous leak or new leak from collector tanks.
• Ground handling wheels have started being serviced in regards to moving aircraft to the front of the hangar to use with AC generator.
• Ground handling wheels bay serviced and tested on aircraft ready for
moving to front of hangar.
• Fuel leak investigation continued – coupling at bottom of starboard main tank found leaking and seal replaced.
• Nose bay rebuild continued.
• Transportation joint completed.
• Tail rotor PFCU started to be refit.
• MRGB hydraulic adaptor began to be fit with new O-rings – one adaptor
found to have been previously cross-threaded.
• MOD 0527 cover plate fitted and PRC’d.v
• Hydraulic adaptor threads recut to allow hydraulic pipes to be fitted to new MRGB.
• Hydraulic adaptors fitted to new servos along with new O-rings.
• Paperwork and duplicate inspections carried out of MRGB and servos with hydraulic pipes started – awaiting signatures for input lay shafts after gearbox fit to aircraft.
• Paperwork and duplicate inspections of transportation joint completed.
• New forward fuel tank inspected inside and out for potential damage.
• Leak checks carried out of new tank.
• Tank bay removed of old and loose anti-chafe tape.
READ THE BLOG• Fuel system inspected for leaks – no evidence of leaks found.
• Ferry tank connection valve dismantled to investigate overflow – seal found perished, investigation into finding new seal carried out.
• Re-familiarisation with control system and finding AGS to fit components.
• Fore and aft position transmitter fitted under P1 seat.
• Rebuild of ECU throttle box continued.
READ THE BLOG• Fuel system inspected for leaks – no evidence of leaks found.
• Ferry tank connection valve dismantled to investigate overflow – seal
found perished, investigation into finding new seal carried out.
• Re-familiarisation with control system and finding AGS to fit components.
• Fore and aft position transmitter fitted under P1 seat.
• Rebuild of ECU throttle box continued.
• No.5 Drive shaft fitted with new bolts and paperwork completed.
• Centre console rebuild begun buy starting to determine the missing
components and looking for loose cables before applying power.
• Bonding leads fitted to sump panels and pipes in the under floor fuel
system
• Fore and aft and lateral artificial feel spring units slaved into place – filling gaps making it easier to determine what parts are missing/still required.
• Lateral trim servo slaved into place awaiting correct bolts and rigging.
• Centre console build completed – all components fitted in correct locations are plugged in awaiting electrical test.
• Serviceable battery picked up from overhaul.
• Fore and aft and lateral artificial feel spring units slaved into place – filling
gaps making it easier to determine what parts are missing/still required.
• Lateral trim servo slaved into place awaiting correct bolts and rigging.
• Centre console build completed – all components fitted in correct
locations are plugged in awaiting electrical test.
• Serviceable battery picked up from overhaul.
• Auxiliary fuel tank self sealing coupling fitted with new hand made seal –
awaiting leak tests next week.
• Filling fuel system and curing leaks to the venting system as required
• Main tanks cover panels fitted and main tanks filled to approx. half capacity.
• Research into missing avionics in rear avionics cupboard.
• Collective trim servo slaved into place
• Yaw control trim servo slaved into place
• Fuel indication system fault investigated and rectified – further calibration required when aircraft is jacked
• Cut rate gyro cables investigated and con checked to find other ends
• Filling fuel system and curing leaks to the venting system as required
• Main tanks cover panels fitted and main tanks filled to approx. half
capacity.
• Research into missing avionics in rear avionics cupboard.
• Collective trim servo slaved into place
• Yaw control trim servo slaved into place
• Fuel indication system fault investigated and rectified – further
calibration required when aircraft is jacked
• Ground handling wheels bay serviced and tested on aircraft ready for moving to front of hangar.
• Fuel leak investigation continued – coupling at bottom of starboard main tank found leaking and seal replaced.
• Nose bay rebuild continued.
• Transportation joint completed.
• Tail rotor PFCU started to be refit.
• MRGB hydraulic adaptor began to be fit with new O-rings – one adaptor found to have been previously cross-threaded.
• MOD 0527 cover plate fitted and PRC’d.
READ THE BLOG• Fitted new seals to the fuel vent system.
• Completely filled the fuel tanks via the gravity fill system.
• New leaks traced – list of required components made and requests for quotes made.
• AGS fitted to control system and lateral trim servo wire locked.
• Lateral spring unit fitted – awaiting rigging.
• Locking wire holes drilled in bolts for collective trim servo.
• AC power fault finding carried out to get power on aircraft.
• Attitude indicators tested – 1 new gyro and 1 new indicator fitted and tested.
• Static inverter system (back up instruments) fault finding started.
• New blades unloaded and visually inspected.
READ THE BLOG• Most components for fuel system ordered – chasing lead on last few components
• Gyro compass system has been tested and gyro unit found U/S – new gyro fitted and system test nearly completed
• Standby AI system tested – new static inverter required
• AFCS system rewire progressing – awaiting pin extraction tools
• All trim servos fitted, paperwork completed and awaiting rigging
READ THE BLOG• Defueled aircraft completely.
• Fitted new components and seals to fuel system
• Refuelled aircraft and left to check for leaks (none currently evident)
• Research into already embodied MODs
• New rotor brake selector valve started to be fitted to complete a MOD.
• Started preparing engine bay fire wall MOD
READ THE BLOG• AFCS rewiring continued.
• Aircraft defueled and defuel valve removed.
• Defuel valve with new seals fitted to aircraft and all components refitted.
• Aircraft filled with fuel for leak checks – no leaks evident at the moment.
• Tail-rotor rigging process researched and prepped for start of rigging.
• Tail-rotor hub fitted.
• Research into life details of tail-rotor pitch change assembly carried out.
• Tail-rotor pitch change beam fitted. New pitch change rods and bolts required – order placed.
• Tail-rotor rigging started.
• Seized bolts in control system removed, old JC5A removed and bolt refitted.
• Engine serviceability checks carried out on No.2 engine
• ECU prepped for fit – engine stay and various pipes moved to correct side, winch pump removed and blanked off.
• ECU filters inspected and replaced as required.
• Engine bay inspected and prepped for installation.
• ECU fitted.
• Exhaust and cowling fitted.
• Exhaust vent pipe ordered.
• ECU control rigging started
• Gimbal ring and drive shaft connected and torqued
• Lower intakes MODed to same state as aircraft with IR station keeping lights.
• Test fit of lower intake.
READ THE BLOG• ECU Pre-installation checks carried out.
• ECU bay cleaned and pre-installation checks carried out
• No.1 ECU fitted to aircraft.
• Exhaust assembly fitted to No.1 engine
• Panels for rear of aircraft around exhausts refitted
• Port and starboard upper intakes rubbed down and prepped for painting
• Port lower intake prepped and fitted to aircraft
• Gearbox dish mounts fitted
• Paperwork brought up to date and independent checks carried out
• Transponder coding rewire continued.
• Flex Ops written out and organised for inclusion in 700 forecast sheets.
• SEM’s investigation into which are applicable started.
• Rigging of cyclic controls continued – control rods and parallel actuators adjusted.
• Paperwork brought up to date and duplicate inspections started for control system.
• Screws and panels for cabin researched and ordered in preparation for rigging completion.
• Grease/oil guns for driveshaft and tail rotor hub ordered and filled ready for use.
READ THE BLOG• AFCS system BITE checks started.
• Rigging of position indicators for fore and aft and lateral controls started.
• Split pinning of control system finished.
• Duplicate inspections of flying controls carried out.
• Research into operation of ASE and AFCS systems carried out after ASE failed BITE checks.
• ASE and AFCS systems switched on for position indicator rigging and setup.
• Pilots seats inspected and serviced. Service bulletin IGQSB033 carried out.
• MOD’s research continued.
• Intercom and radio systems tested – fault found with P1 intercom system. Research and fault finding started.
• Cockpit panels fitted.
READ THE BLOG• Main rotor head rigging carried out. Adjustment of the pitch links, fore and aft and lateral control rods.
• Control system position indicators set up.
• Cockpit voice recorder fitted.
• P1 and P2 seats refitted.
• AFCS and ASE testing and fault finding started.
READ THE BLOG• Windscreen washing system adjusted and both sides functioned.
• Annual service paperwork brought up to date.
• Blade anti-node weights removed, inspected and refitted.
• MODs research and paperwork continued.
• Pitot static instrument research into calibration carried out and spares sourced.
• Carrying out BITE tests of AFCS and ASE systems (on going).
• Investigated blade tracking procedure and equipment.
READ THE BLOG• AFCS and ASE system testing, BITE tests started and fault finding problems.
• Replacement hydraulic pipe in No.1 system fitted – leak solved.
• Wire locking and testing of hydraulic system.
• Dish fairing drain for starboard side fitted.
• Testing of RNS252 – fault finding required.
• Testing ADU – more tests required.
• Static inverter replaced and standby horizon tested.
• Confidence duplicate check of main rotor head rigging carried out.
• Fault finding rate gyro system.
• First batch of pitot static instruments send away for calibration.
READ THE BLOG• Sliding fairing refitted.
• Duplicate inspections and paperwork brought up to date.
• Major service continued (tail rotor inspections carried out).
• Sorting and batching of new parts.
• ASE and rate gyros testing and fault finding continued.
• Tail rotor gearbox and servo inspections carried out.
• Torque systems tested to ensure correct engine torque codes.
• Tail panels refitted.
READ THE BLOG• MOD’s research continued.
• Both AC generators fitted and wired up.
• Accessory drive actuator functional tested.
• No.1 engine prepped for ground running.
• Sorting of spare components continued.
• Aircraft and bay moved to front of the hangar to facilitate fuel flow checks etc.
READ THE BLOG• Preparation for ground runs.
• Instruments refitted.
• Loose components bolted down.
• ADU tests started.
• De-inhibiting and bleeding No.1 fuel system.
• 3 successful ground runs of No.1 engine.
• Minor defect rectification post ECU start.
• Big ‘BZ’ to maintenance team.
READ THE BLOG• Fuel leak from No.1 ECU traced
• Engine removed for access
• Oil scavenge pump gasket changed
• Engine refitted
• Starter generator replaced
• Wet and dry runs carried out to bleed fuel system
• Minor instrument snags rectified
• Torque meter test procedure researched and gauges tested
• Rad alt system tested and new gauges fitted
• Engine and airframe prepped for ground run
• No.1 engine run up to 95% power successfully with no problems
READ THE BLOG• Engine and airframe prepped for ground run
• No.1 engine run up to 95% power successfully – AC power snag found
• No.1 AC system Control and Protection Unit replaced
• AC power generation functional tests carried out and found satis
• No.1 DC generator tuned to give correct output under load
• 1 hour total further ground running carried out on engine
• Standby Horizon found inop on ground run, snag investigation on-going
• Various magnetic indicators found sricky/inop, being replaced
• Serial numbers of major components found and listed for paperwork
• Lynx spares packed into container
• Investigation of method required to modify audion system for acceptance of 8.33 radios
READ THE BLOG• USB charging socket install started
• 8.33kHz radio install started
• Inventory of new serviceable ADU’s and AFCS computers taken after unpacking
• New ADU fitted for transponder tests
• New transponder control unit fitted and transponder tests carried out,
all modes functioning Satis.
• AFCS system testing continued – replacement CAC required.
READ THE BLOG• Radio remote head metal work completed
• Wiring and circuit breakers for remote head and USB run through centre console
• Replacement starter motor fitted to No.2 engine
• Fuel flow light panel repaired with new filaments soldered in
• No.1 ECU L.P cock magnetic indicator replaced
• Replacement CAC fitted and tested – satis
• AFCS system functional tests continued
READ THE BLOG• Wiring for USB and radio remote head unit continued.
• Aircraft prepped for ground runs.
• No.1 ECU ground runs carried out successfully.
• Research and testing of BAR ALT hold system.
READ THE BLOG• Annual inspections continued
• Ground use only rotor blades test fitted ready for show
• Panels and fairings refitted for show
• Lateral position indicator wire locked and repanelled
• Rotor brake control wire locked and repanelled
• Wiring for radio and USB continued
• Radio mounting tray installed
READ THE BLOG• No.1 and 2 ECU’s removed.
• 2x stub shafts changed for serviceable components with life details
• No.1 and 2 ECU’s refitted
• Calibrated pitot static instruments retrieved and batched in ready for fitting
READ THE BLOG• No.1 and No.2 ECU refit finished
• No.1 and No.2 Air Intake assemblies refitted and oil cooler fairings refitted.
• Port and starboard cabin door rail and carrier assemblies lubricated and refitted.
• Port and starboard cabin doors refitted.
• Pitot/static instruments removed from instrument panels and serviceable items fitted.
• Fire bottle system tested for serviceability and found satis.
• GPMG mount test fitted to starboard door.
• Footstep and night-sun test fitted to starboard skid.
• Footstep test fitted to port skid.
READ THE BLOG• Nose bay door seals replaced
• Wiring inspections completed
• RTI inspections carried out
• Rotor head damper bolts replaced IAW RTI
• Aircraft alignment checks carried out
• Environmental control system Teleflex locked and split pinned
• No.2 ECL range adjusted and locked
READ THE BLOG• Aircraft de-jacked after alignment checks
• Aircraft prepared for ground running
• AFCS system fault finding/testing
• Ground run carried out
• Replacement controller engaging ordered
• MRH spider arm wear check carried out
• Crash switches test looms started to be made
READ THE BLOG• Aircraft bonding checks completed
• Fault finding of aircraft crash switches carried out – new fire bottle cross feed switch ordered
• Unloaded XZ678 after arrival
• XZ678 cabin unloaded and sound proofing removed along with interior and cleaning started
• Serial numbers for engine and driveshafts collected for checking life details
• Sorting and batching of new spares
• Fault finding of No.1 torque indicating system started
• RTI’s investigated
READ THE BLOGXZ179:
XZ678:
XZ179:
• Doppler radar removed, inspected, resealed, refitted and tested
• Paperwork gone through prior to CAA visit
• Airworthy blades cleaned and inspected
• Airworthy main rotor blades fitted in preparation for ground runs
XZ678:
• Airframe survey completed
• Forward and starboard collector tank sumps removed, stripped and cleaned – collector tank sump still to be rebuilt and fitted.
• Transfer pumps removed from donor sump and fitted to forward tank sump
READ THE BLOGXZ179:
• Fault finding vertical gryo problem ground run
• No.1 voltage regulator replaced
• Main rotor blade sleeves oil replenished
• Sound proofing fitted to aircraft
• Post ground run inspections carried out
• Preparation for ground run carried out
• Rotors turning ground run carried out
• Cabin environmental control system tested
READ THE BLOGXZ179:
XZ179:
• Prepping aircraft for ground runs
• Fitting tracking equipment
• Ground tracking runs carried out
• Tail rotor balancing within limits
• Main blade tracking moving towards being within limits nicely
• AC line contactor replaced
READ THE BLOGXZ179:
• Investigating adaptors required for comp wash coupling to comp wash rig
• Fault finding faulty mag indicators
• Starboard rear traveller wheels stripped and resealed
• Investigating fuel indication functional check and carrying out check
• Ground run of No.1 ECU to test electrical systems after changing line contactor
• Hydraulic cooling fan replaced
• Loose hydraulic pump union found and rectified
• Aircraft prepped for more ground tracking runs
• Paperwork closed down as much as possible
READ THE BLOGXZ179:
• Post first flight inspections continued
• Hydraulic Cooling Fan failure investigated – fan found U/S
• Investigate failed magnetic indicators and replace as required, one found to require new pin.
• Investigate AFCS Yaw Lane 1 snag
• Remove and replace No.2 FCU Throttle Control Valve
• Bleed FCU post replacement of Throttle Control Valve
• Carry out throttle pressurising valve test
• Tail Nav Light bulb replaced and tested satis
READ THE BLOGXZ179:
• Aircraft prepared for ground runs and flight testing.
• Main Rotor Gearbox flushed and filled.
• Aircraft ground run for leak checking of No.2 ECU Throttle Control Valve and Main Rotor Gearbox sump plug – all satis.
• Aircraft hover tested – functional test of AC system found No.1 AC Control
and Protection Unit to require replacement.
• No.1 Control and Protection unit replaced as required.
• Aircraft ground run and functional test of AC system carried out – found satis.
• Aircraft further hover tested, aircraft taken into circuit of airfield.
• No.2 AC Control and Protection Unit removed and replacement item fitted
(requires wiring up).
• Investigate tail rotor hydraulic cut out system after having been found intermittent.
READ THE BLOGXZ179:
• Newly arrived blades from Everett’s unloaded
• Blades cleaned and inspected externally, potentially serviceable blades put to one side
• Anti node weights removed from potentially serviceable blades, cleaned,
inspected, refitted and re-sealed.
XZ179:
ZD252 (G-NCKZ):
• Various newly arrived components and AGS inspected, batched and logged.
• Port collector tank low level float switch tested, found satis.
• New ring tags fitted to port collector tank low level float switch and float switch fitted.
• Cables in area of port collector tank low level float switch re-loomed as required.
• Fuel pipes in stbd aft belly bay removed for cleaning and inspection.
• Fuel pipes from stbd aft belly bay cleaned and inspected, found satis.
READ THE BLOGZD252 (G-NCKZ):