Quote Originally Posted by Ode to a Grasshopper View Post
There's a trick to it - the waist/thigh-connector piece (which faces with the cover up in robot mode) has to be facing down in 'copter mode. Basically when you look at him upside-down the front-facing thigh joint should have the joint visible, and the rear-facing/under-cockpit-bit thigh joint should have the top part of the 'cover' showing. Once you put it like that then it tabs in pretty securely.

Check the TFW2005 thread if you need pics, or I can take some later if you like.
Cheers Odey, managed to work it out and it does sit a LOT nicer. In my travels for information on this one, I found the Hasbr transformation video and even they didn't get it nice and tight.