May 12, 2024     Started fitting electric motor mount - (4 hours)       Category: Engine

Started fitment of motor mount. This is an off-the-shelf Sonex electric motor mount and a Zaero brand electric sub-mount. To do this, I:

- measured the length of bolts required for both the main and sub-mounts these will be ordered from Aircraft Spruce
- Determined how the rubber mounts work

  Jan 29, 2022     JUMPING COMM RADIO FREQUENCY - (2 hours)       Category: Engine

The FlightBox Pro arrived with v3 software upgrade. Testing revealed:
- XPDR seems to work
- COMM radio frequencies displays random numbers, rendering it useless
- Bug reported to Steve Sokol
See: https://youtu.be/wOw7YcTaboI

  Jan 29, 2022     Understanding Redrive System - (2 hours)       Category: Engine

Got a call from Gabriel Devault, inventor of the Zaero redrive. During and after the discussion, the following points were revealed:

Bearing maintenance
Q: How long do the bearings last?
A: Three answers:
1. Recommended replacement of Zaero and motor bearings at 1000 hours.
2. Preflight and annual / 100 hour inspection item: Listen and feel for growling or other unusual noises like high and low frequently rumblings or thumping from redrive system including two redrive bearings and Zero motorcycle motor bearings.
3. The SKF bearings used in Zaero and motor are identical. A bearing calculators was used to validate loads in this application. See photo below of a calculator.
The Zero motor controller monitors temperature and displays warnings to pilot. For the Zaero I suggested pointing an infrared temperature sensor at the hub housing the two bearings and displaying to pilot in flight.

  Jan 27, 2022     Received, unpacked and inspected Zaero Redrive kit - (3 hours)       Category: Engine

MAJOR PROGRESS
Received, unpacked and inspected Zaero Redrive kit

Sent Email to Flit LLC:
SUMMARY: Send a throttle, main sprocket and sprocket retainer.

DETAILS:
I am ecstatic about receiving the Zaero kit. Thanks for installing the bearings.

A little waxing philosophical, if you will: In this life, after everything is stripped away, all you have is your reputation. The Zaero kit has a stellar reputation as far as concept and design. May I make several suggestions?

- Communication
- Quality control

COMMUNICATION
1) Delivery
The original delivery estimate was 12 weeks. Actual was 20 weeks.
For a prototype, the delivery time was acceptable, but resetting expectations should be done early in the process. Being a pilot trained in worst-case analysis, I thought my Zaero investment might be a total loss because of the loss of communication.

2) Instruction
There were extra cables and one bolt included in the kit that I don't understand. A parts list and assembly diagram would aid in understanding:
- Spare bearings. Bearing orientation. Pressing technique.
- Mounting bolts to buy
- Washer type and quantity
- Belt tension and XYZ adjustment points
- Torque specs
Maybe I can help you make such an instruction sheet, once I figure it out. LOL

QUALITY
3) Missing throttle. See photos. Please send one.
4) Damage in shipping. Packaging was inadequate to prevent damage. See photos. Please send two new parts to replace:

- damaged main sprocket
- dented belt retainer on small sprocket
- scraped and chipped paint and metal on mount. Just let me know what alloy was used and I'll file the burrs and re-paint.

  Sep 28, 2021     Ordered electric redrive kit - (2 hours) Category: Engine

Ordered electric redrive kit from https://flitllc.com/

  Sep 28, 2021     Bought Zero DSR Motorcycle - (10 hours) Category: Engine

New DSR will donate it's motor, battery and controller.