1/2 Scale ACA Hurricane MKII

RIP Black Darien Hurricane 💔

1978-May 29th 2021

Gone but not forgotten.  May your soul live on through this faithful ½ scale miniature ❤

This is my tribute to you, my friend.

This project was in development for one year and 9 months.    Project started in April, 2023 after the Greg Nieport chopper Hi Lo video resurfaced.  That video finally let me know what the MKII chopper assembly looks like!

HUGE SHOUTOUT to Israel Jones (TexasRailfan2008) for providing me absolutely fantastic rotator measurements and references.  

And another huge shoutout to my awesome friend Demetrius Padilla (YourAverageMODude145) for all his tons and tons of help with modeling this siren's horn and chopper assembly, and tons of prototyping with the chopper assembly!

Demetrius made the Civil Defense logo in the last picture.  Feel free to have a sticker printing service print that so u can put it on your rotator covers!  You need it to be printed as a 5" diameter circle.  I recommend Printmoz.com

This siren is 100 percent outdoor service safe!  Just print the Horn assembly and rotator covers and outer rotator tube in PETG at minimum.  Otherwise it will probably warp in the summer.

  Everything is already in the correct print orientation. 
 

Print rotors, rotator tubes, and flange in 99 percent infill.  Chopper tube I suggest 99 percent infill.  I do not recommend any lower than 90 percent infill for the chopper tube.

CCW is for the bottom, CW is for the top.  For whatever port ratios you are doing, have the low tone be CCW and the high tone be CW.

Recommended motor is a Samsung DE31-0028W.  But this is compatible with any 2.8/2.85" samsung motors.  28X, 28W, 28Y, 28N, 28P, etc etc

Chopper uses a 10uf CBB61 capacitor. Then hot glue it to the 8 port stator.  I used mini wago connectors to join the motor and capacitor wires. https://a.co/d/06Pg4yEe This is the capacitor I used.

For the motor's power wires and collector ring output, I used ¼" INSULATED spade connectors.  (MAKE SURE they are insulated so u don't get a 120v short and possible fire inside your chopper tube)

https://shop.advanceautoparts.com/p/dorman-22-18-gauge-male-female-set-fully-insulated-quick-disconnect-.250-in.-red-85460/12066731-P (I walked into my local Advance Auto Parts and got these.  They fit very tight, so i bent the female one a bit to loosen it.)

I used 18 gauge wire for the collector ring output.

Collector rings are 3.5" OD aluminum pipe with 2mm thick walls.  Cut to approximately ½" tall sections and secure to the outer rotator tube using a bead of hot glue around the edge.

https://www.amazon.com/dp/B07WD82W6S?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

This is the aluminum pipe I used.

 Then you use two 10mmx5mmx5mm carbon brushes inside the brush holder.  https://www.amazon.com/gp/product/B07DYW5ZY7/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1   These are the brushes I used.

The horn sections all print without supports.  Just use a brim.  To join them together, weld them together with a soldering iron.

The chopper tube needs supports on the undersides of the throats and fairings.  inside the tube, and inside the holes and inside the throats prints supportless.

When joining the throats to the chopper tube, first run hot glue around the slip on point on the chopper tube.  Then very quickly push the throats on and hold it until the glue cools.  Stand the assembly horn down and then use your soldering iron to weld the joint.

Hardware:

4x M4x30 machine screws

4x M4 nuts

 (hold rotator to the blower pipe flange)

6x M3x16 machine screws (brush holder terminals and main rotator gear)

45x M3x10 machine screws 

(mount chopper to chopper tube)

(mount rotator covers to the rotator)

(everything on the rotator except what the M3x16's are for)

13x M3x6 machine screws (clamping rotator covers together)

68x M3 nuts

36x M3x5.7 brass threaded inserts (main rotator tube, chopper assembly mounting holes, and brush holder)

4x M3 ring terminals (these fit to the terminals on the brush holder and the rotator bracket)

I recommend getting insulated ring terminals.

AC Rotator Motor

4x M4x20 machine screws

4x M4 nylon insert lock nuts

(hold the slip clutch together, and keep tension)

1x 7mm shaft flange coupler with M4 screw holes and 24mm bolt circle spacing.

https://www.amazon.com/dp/B07PFWQ8H9?ref=ppx_yo2ov_dt_b_fed_asin_title

I used these ones

https://www.amazon.com/dp/B014HLLTOS?ref=ppx_yo2ov_dt_b_fed_asin_title&th=1

This is the rotator motor I used.  You need a 6rpm one of these.

Rotor installation:

 8mm to 8mm 14mm OD 25mm L shaft coupler 

https://a.co/d/0iklOR8R

10 gram slotted weights (20x)  This link gets you 3 rotors worth of weight!  

https://www.amazon.com/dp/B0D2Q2QW43

To secure the weights, simply push them into the bottom of the rotor.  They should just slip right in.  If needed, you can tap them in with a hammer.  These are made of steel, so it should be alright to take some hammer taps.

Put a set screw in both top holes on the shaft coupler.  leave the bottom two screw holes empty.  Then tap the coupler into the rotor from the top with a plastic mallet or plastic screwdriver handle. 

Make sure the set screws are lined up with the access cutouts in the rotor hub.  Don't use a hammer, you can damage the soft aluminum.