Ok let's do some surgery. I've downloaded Hovercontrol_412_PE_v1_FSX
and extracted its contents into a temporary folder. This enabled me to compare it with Hovercontrol_412_PE_v1, the FS9 predecessor to the FSX version.
Obviously they had to make changes to the installer as in the old version the path was Flight Simulator 9 / Aircraft -- and now in the FSX version the path is SimObjects / Rotorcraft.
I looked at the 'docs' folder which in both versions contains the same single word.doc: Hovercontrol_412_Checklist.doc. I began to compare the contents of both .docs but gave up after a while because they appear to be identical.
Then I compared the gauges. Hovercontrol like some other freeware developers use .CAB files for their gauges and leave them inside the panel folder. AFAIK these .CAB files are usually compatible with FSX.
One little difference here which shouldn't trouble us but which might be worth mentioning:
The FS9 version contains one .CAB file in the panel folder: HC412.CAB
The FSX version contains TWO .CAB files in the panel folder: HC412.CAB and Cessna208B_XML.cab.
So now I had to check whether the texture files had been changed from .bmp to .dds, reason being, the old .bmp files that were used for FS9 textures are compatible with FSX -- but not the other way around. If the .dds files which are now used in FSX are loaded into FS9 you'll most likely get a CTD.
Now I better tell you why I actually went through this procedure: If I could safely install the FSX version of the helicopter into my FS9, I could fly it and see if it would start smoking like yours 🙂
Well, it didn't - I flew for about ten minutes, exited the sim and did the same thing again... no smoke, no fire, no problems.
When the Hovercontrol people told you to load the default C172 first and THEN change to the helicopter that was sound advice; this procedure can solve the problem of not being able to load complex aircraft. But why the smoke reappeared regardless is a mystery.
I'll have to digress a little and hope that I'll find my train of thought again.
Strangely, the FS9 version of the helicopter contains 10 flights... the FSX version does NOT include any flights. 'Maybe' because they are not compatible due to different scenery and have been substituted with the 'Missions' in FSX.
ALSO, the instructions stated to open up a new flight, tell it "OTHER", then load one of the "base" hovercraft flights, save it and restart, then ALL would be well with the "engine" problem...................well, I have an OTHER folder under flights, but it does not show up in FSX..............
Regarding this I can only relate to my experience with this helicopter in FS9.
If I create a flight ie. start the sim, load the default C172 and then switch to the helicopter, the engines will be running and remain running.
On the other hand if I select one of the Hovercontrol flights, it'll take me to the location etc. and the engines will be running but be in the process of powering down. Even if I jam the throttle, the engine will finally turn off. NOW... in order to power up the engine again, I HAVE to go through the start up procedure. If my concentration has been overstretched but I want to fly now, I need to actually shut the sim down and start it up again, and create a flight. I'll find myself in the aircraft with the engines running.
As will be obvious by now there is no use for me to download a Mission as I'm running FS9.
Regarding the fire and smoke issue I very much doubt the problem is caused by the helicopter or its installer. They are very reliable and straight forward.
I'm calculating that the problem is a remnant of a previous flight or add-on - even if that's not the case, files can and will become corrupted, therefore I'd suggest you delete your FSX.cfg file. The sim will create a new one free of mistakes the next time you start up the sim.
Also, in your My Documents folder resides a sub folder called Flight Simulator X Files or similar which contains the flights YOU have created. Often the gremlin hides in that folder so it's a good idea to delete that as well. The sim will create a new, gremlin free folder the next time you start it up.
I really can't think of anything else ATM but if it's any consolation I doubt that the issue is a major one that couldn't be solved with minor tweaking.