https://lukeattubato.com/projects daily 1.0 2023-02-24 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558713681330-593UYX3W26L6TDN9STSA/26+IMG_9965.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563298301232-LTTKRMES3SEAMIYKO23U/50++IMG_9279.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564155686205-6ZAY1PG8Q0HE60PGQ0I6/IMG_20190507_194104.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563890706735-EAF5K6KUEQG7HFJ7LF8K/IMG_0164.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563890951401-C2Y2O3WFM95SQ2LEZ7P6/IMG_0158.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563891211599-KZWEU7PFMICBOAXE5Z6W/IMG_0173.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564007411874-MSHJTU8FKR33FKDIP3OG/IMG_0194.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574023873412-CE6JFVFLN174MR6VMQR1/IMG_0111.JPG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583016030739-09U1B3W88WNRP0C6RUHP/IMG_0746.JPG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583931078969-Q6LK44ZS566KN8C3H2Z5/IMG_0077.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583932696212-T7KFRJ4BKJXDD7BX2BD9/IMG_0769.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367599915-1FE4OXVC3RE3Y1496BGX/Capture.PNG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592443783-IS4R3P49TIOLQAJPYQQW/26+IMG_9965.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563656214931-6L4L808P9EC0L9Z42UMG/1%2BIMG_8930.jpg Projects First off was the Lithium Ion battery mod, I decided to use two lithium cells in series to roughly match the voltage range of the 6 NIMH cells the transmitter comes with. I chose NCR18650B’s because they use the increasingly common 18650 form factor and because they have a high volumetric energy density of 675 Wh/L compared to around 450 Wh/L for a standard lithium polymer soft cell battery or a NIMH cell with as low as 200 Wh/L. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562595823687-YBS1M6GKGJ875BEBWJ58/4+IMG_8934.jpg Projects I connected up the new module to backs of the pins that extend out into the module bay. I then cut the trace between the Q2 mosfet and the V+ pin that goes to the module bay so that I could insert a switch between them, so switch between powering the module bay (and therefore the long range R9 system) and the internal DSMX/DSM2 module https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703398002-C5KQX6KJ0OZLU39Q9LGU/image-asset.jpeg Projects I next found a suitable place for the new transmitting module in the transmitter and drilled a hole in the case of the transmitter for the antenna extension cable to exit the transmitter. and then I glued it down with hot glue - since it should never heat up too much. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703416242-AMDGRUPAM4XUR51ARMH7/image-asset.jpeg Projects I added a power distribution board (made from perf board) to step down the 5V from the Taranis to the 3.3V needed for the module (both supply and logic levels) roughly according to the diagram below that I found at : www.flitetest.com/articles/spektrofy-your-taranis https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562594816282-BIG3WY2X7IGWKO4YX5Y3/editor_images_1520102660440-1520102660440.jpg Projects Wiring Diagram : www.flitetest.com/articles/spektrofy-your-taranis https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703584247-5M5CILSOKJ6C4O5RN3PR/image-asset.jpeg Projects I installed the receiver for the wireless trainer system in the battery bay. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703594659-LGZUEXIH7V7RME753LP4/image-asset.png Projects The CAD model for the new battery bay door, This part will allow me to mount switches on the back of the transmitter and allow for the new form factor of the new 18650 batteries. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703607352-5689FDGE0TZEDUIKY96L/7+IMG_8940.jpg Projects The 3D Printed battery door with the battery https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1558703628296-51HI9D6YM2QMCKF3OB9H/image-asset.jpeg Projects This connector is used to balance the voltage of the 18650 cells and to connect to the 3rd joystick which will be mounted of the back of the transmitter https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591738038-3214WJ3LDMF06SS8WUUE/image-asset.jpeg Projects Battery glued into the battery bay and the switches for the transmitting modules (right) and the receiver for the wireless trainer (left) installed https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591897366-P6386091TF8HDQSE1K7O/12+IMG_9963.jpg Projects The battery bay on the back of the transmitter with the charge leads connected. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591771660-81LQ3N89HWN49MQ1OYGW/10+IMG_8957.jpg Projects Midway through the mod I found three unused pads on the mainboard of the transmitter. At first, I thought they were diagnostic pads, but there placement and silk screening seemed to suggest they were for a 3 position switch. After some research I found they were for a potentiometer input that was never used from the factory. I decided to install a 6-position rotary switch which emulates a potentiometer with a resistor array. This is to make it easier to use for changing autopilot modes. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591950331-ICN5I69KU97CDRUMRT6W/13+IMG_8953.jpg Projects The wires for the new joystick spliced into the wires for the potentiometers mounted on the front of the transmitter. I rarely use the front potentiometers, and having the joystick in parallel with them will mean that I will be able to use them as ‘trims’ when using the joystick and I will be able to control the pan and tilt with the potentiometers when not using the joystick. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591980966-1RW7G86JQCDDZ85EMZUZ/14+.jpg Projects The green multiplex 6-pin connector is used to bridge the two halves of the case https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591847629-R7OY0EUJ5YYB655QDQ37/11+IMG_9962.jpg Projects The third joystick mounted on the back of the transmitter with 3M Duallock so that it can easily be removed when not needed. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562591999841-NEFDYT0VURMHT6E06Z4K/image-asset.png Projects The CAD design for the new handle with integrated antenna mounts. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592094926-CQOD2A13CKWP8A9TYNDW/image-asset.jpeg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592051064-NLPKN3EKYH9941IH1URQ/16+IMG_8962.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592130997-OPCA2062NKDC6RRK5OH8/18+IMG_8973.jpg Projects The back half of the case, particularly showing how I’m routing the antenna coax through the case. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592255426-I12WYL0CALDY7ZM9SWH4/21+IMG_9327.jpg Projects The 7 pads shown here all go to a standard 2 channel + ground 3.5mm jack socket, I found that the other 2 of the other 4 pins are a normally closed indicator for when a jack is in the jack socket with the other 2 of the 4 being the same but normally open. It turns out that the transmitter will not enable trainer mode unless the first 2 pins are open (jack plugged in). So to bypass this I cut the trace between this switch and the ‘sense trace’ going to the mainboard on the transmitter and instead connected it to the second pole of the double pole switch that I am using to power the wireless trainer receiver. Unfortunately, this now introduces another problem, because now to use the standard wired trainer port I would have to have the wireless receiver powered as well to activate the trainer port. This could cause interference in the signal going to the transmitter. To get around this I just used a 10k resistor between the wireless trainer system receiver and the transmitter mainboard, this is not a perfect solution, but in practice allows the signal from the wireless receiver to be negligible compared to the wired port when they are both in use https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592212172-ZLBI8RTO0EFM9Y7W36NS/20+IMG_9325.jpg Projects 32awg jumper wire soldered onto a 0402 resistor and better view of the cut trace. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592277093-56AT375E64HV4EO7UWPS/22+IMG_9329.jpg Projects Red wire soldered to the source of power I found that is only on when the transmitter is powered on. This means I can’t accidentally drain the transmitter battery with the wireless trainer system. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592325511-TAOLD8XVO9TFZTAKG2E8/24+FPV+Watch+Mount+CAD.PNG Projects CAD model of the screen mount for the front of the transmitter https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592303955-VVG4VHMOWMOJKSQ7T7SL/23+IMG_9417.jpg Projects A ‘hardwired’ power source for my long range module that I can use for higher risk flights when I don’t want to trust the funny buisness going on inside the transmitter, not that I’ve been given any reason not to trust it yet. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592350567-R9APCR49Q0TNV0BXLJE2/image-asset.jpeg Projects Screen mount attached to the transmitter. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1562592379168-IKY66QBQ3FIRD2JJETR0/26+IMG_9965.jpg Projects The Finished unit https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563822975559-LLDQW78US7YKZT810C98/IMG_0164.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563823235983-TTM6HRIT82S7C916TKGK/IMG_9928.jpg Projects 3d printed panning plate with one diversity 5.8GHz receiver fixed on it. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563823388640-FF2AB07M98WOU8ABQRTW/IMG_9930.jpg Projects The servo used to drive the pan plate. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563823571109-RKHQFG5RL9ERF8CBFKUO/IMG_9943.jpg Projects Disassembling the DVR that I want to use to record the video downlink. I’m having to take it apart because it uses a 2.5mm jack for video input as standard, which I’m not particularly happy with. Its loose causing it to occasionally lose connection. Instead I will just be direct soldering to the pads. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563823808777-9VRYXP7D12Z45XAD5V1W/IMG_20190518_185937.jpg Projects The completed antenna tracker. The two red patch antennas on the left are the antennas used for tracking, and the blue helical antenna on the right is the antenna used for receiving the video signal. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563298444759-98J3C5ANIZGVAD74GGIK/50++IMG_9279.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563318755765-QU065ENBMPULSAOCXXTC/xuav-minitalon-kit.jpg Projects X-UAV Mini Talon https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563318821561-JTIS4MEPQT674JPYXAXO/mytwindream.jpg Projects MFD Twin Dream https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563319026453-VV70OU67G4XK08YKB0CH/12190890_1096711227005805_3777218305750131891_n.jpg Projects Ritewing Drak https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563319005465-RJH4QHTD6JPXYI0O9HVO/maxresdefault.jpg Projects E-Flite Radian https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299151033-9MLNF88G8H7WWLPYOISW/1+IMG_9038.jpg Projects Build started by gluing the 3d printed wing ribs onto the main carbon spar with 2 part epoxy resin and then gluing that to the bottom wing skin to make the centre section of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299310223-2GEC4DUPEI9X3MPMMXGB/04++IMG_9079.jpg Projects Moutning the left outer wing section to the centre wing section showing the joint between the carbon wing spar and the radio signal friendly glass fibre spar. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299922793-A7U2TNC3V07PHZMWEII1/08++IMG_9103.jpg Projects Main receiver mounted in the left wingtip with the two antennas mounted at 90 degrees to each other. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300521889-H5ZW9MKYQ1QD7KTQD0Q9/13++IMG_9135.jpg Projects LM317T Voltage regulator set to 6V for the right aileron servo. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300622830-KAJRFILIDZISQVS7FPSG/16++IMG_9148.jpg Projects On the left is an LC filter to smooth the supply voltage going to the video transmitter, for cleaner video. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300832949-H4YVFDQ5YMBPRJSUQL13/18++IMG_9152.jpg Projects Receiver wires all connected up. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300884844-DLA5JHO5ZXHJMRZ861IF/20++IMG_9201.jpg Projects LED chip mocked up on the leading edge of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300957093-FPTKTTK3JQ099YTEZ8CQ/22++IMG_9154.jpg Projects Working out how big I want the fuselage to be, using 2200mAh 3s LiPo batteries for reference. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301018555-T2QYZGR358XXAAY6W7MC/24++IMG_9171.jpg Projects Fuselage mostly glued together with an opening at the front for cooling air to pass through the fuselage, this may be covered up later, depending on compenent temperatures insdide the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299249878-8EL9UTOV7ZP5O56NWZ1H/2+.jpg Projects The centre section of the wing done with the original cables hanging out, these were later replaced for more compliant silicon cables. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299277430-O3JH948D6QHTC38PRB8C/03++IMG_9067.jpg Projects View showing the internal structure of the centre section of the wing. Note the motor controllers mounted inside the wing between ribs in the centre. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563299886239-VS811RG69T2HZ27VMLBK/07++IMG_9091.jpg Projects Emax ES08A ii Servo mounted in the outer left wing section, its glued directly to the main spar for extra rigidity. Also note the new silicon cables. 12 signal wires and 2 power wires go out to the receiver on the left wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300138522-PQR7Q9IKSNWS4Q4NJAHB/09++IMG_9117.jpg Projects AKK X2 Ultimate video transmitter being mounted flat with hot glue ouside the wing on the right wingtip. It is as far away as posible from the control receiver to limit interference and outside the wing for cooling. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300549385-OSO933QAOMLHPKN74U1V/14++IMG_9139.jpg Projects Heatsink for the voltage regulator bent down into the airflow below the wing for cooling. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300799790-8PIDJHUHLFDI556VMYWP/17++IMG_9151.jpg Projects As always, joints in wires are spaced appropriately so that it doesn’t casue a large bulk in the wire, and reduces risk of shorts if the insulation fails. The joints are insulated with clear heat shrink for easier inspection. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300855141-UROHQVMC6YQTPBQ6YJRR/19++IMG_9198.jpg Projects 3w LED Chips that I’ll be using for both navigation and strobe lights. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300919950-ET5SDTG72J7S86O7OATH/21++IMG_9202.jpg Projects LED mounted interally makes the entire wing glow, aiding visibility. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563300993594-TG5981STPKTOIKFH2WTN/23++IMG_9156.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301083724-J1NCKO6657M6VFR7GGBU/25++IMG_9177.jpg Projects Mounting of the tail boom into the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301165229-ZPDHYPEP9W610HPQG2PA/27++IMG_9183.jpg Projects 3d printed V-tail Support piece. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301364644-7HU3XWR05THXNLEBG10A/31++IMG_9196.jpg Projects Servo glued into place in one V-tail half. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301118945-PMSVU46CD02KEWCAENMH/26++IMG_9178.jpg Projects Flaps on the bottom of the fuselage to acces the battery area. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301236168-RGOH1WCBE2M9BG3AJ49V/28++IMG_9185.jpg Projects Foam peices for tail with laser cut plywood strips glued into them for extra strength. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301299286-EG3OZ16ZIJ3FQCZL8QTA/29++IMG_9192.jpg Projects Both V-Tail halves. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563301989112-L6HZY7JDUK0SFUM7KLZD/32++IMG_9208.jpg Projects Both V-Tail halves dry fitted in place with servos glued in place, this will come back to haunt me later. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302034125-TYYACKT982P17OWXBIVP/33++IMG_9216.jpg Projects Servo linkage to the ruddervator. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302063421-FHZV4RN35GTQ8OTH3WF9/34++IMG_9220.jpg Projects Comparing the weight of three Matek 5V Switching Voltage Regulators which are capable of a constant 2A to one LM317T Voltage regulator. (Three units are shown here to get a more accurate reading from the scales) https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302823676-Z42JX50NOG295AJNDEOO/37++IMG_9227.jpg Projects Weight of the 12 stands of 30awg and 2 strands of 18awg silcone wire that is run to the tail. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302914041-38DNGBLWQU0JDSLN8WBB/40++IMG_9241.jpg Projects My first wiring harness between the wing and the fuselage, this is only for initial test flights since later I will be installing the autopilot. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563633317386-WM671VVGTA8M30SU3M5Y/46%2B%2BIMG_9254.jpg Projects Left outer wing section just before being glued together. Note the expanding glue along the front join to add strength to the leading edge to prevent handling damage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302757147-HKD1OR6PQ091L4SYK1FN/35++IMG_9222.jpg Projects The LM317T voltage regulator both weighs more, is less efficient and can only supply 1a, however since it is a linear regulator it doesn’t introduce switching noise, so I’m using it on the right wingtip near the video transmitter where I need a very clean power supply. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302848758-357D3K5MWWQBN6NL8QA2/38++IMG_9230.jpg Projects Wires exiting at the tail. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302876002-T3S9XL22YG0B3J1N2ETM/39++IMG_9238.jpg Projects Tail servo voltage regulators mounted. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563302963233-VQAJX7KAMTDWYLGZY416/41++IMG_9245.jpg Projects Wing rubber band tie downs mounted in the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303110150-VTPIGBJOYIPK12DOHBHV/44++IMG_9251.jpg Projects Right outer wing section before being glued together. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303229486-HF6GRUE2BHUB4PF65HMD/47++IMG_9263.jpg Projects Aileron hinged using 3M Blenderm Tape. Note the beveling on the wing side of the joint that should have been done on the insde surface but I forgot to do it before gluing the wing together. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303292276-XA44YDM777359JSJVDSD/48++IMG_9265.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303330777-KGQXM68NSTDW88BPGVOA/49++IMG_9273.jpg Projects Battery placed in the battery bay. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303368640-8KG0S01BBAH3CBU1ZFRD/50++IMG_9279.jpg Projects All ready (or so I thought) for the first test flight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303401535-29TAOP4N42QRROHALW5Q/51++IMG_9282.jpg Projects I had forgot to glue in the tail fins after I had dry fitted them a couple of weeks ago, luckily, the servo wire of all things was holding it in, otherwise the test flight may not have been so succesful. I got very lucky. I glued them in properly and continued doing test flights. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303422774-70A4TC7GTNWIC0OEP0WY/52++IMG_9285.jpg Projects After 20 flights the bottom of the fuselage is stil holding up fine to landings and takeoffs. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563635862124-V7WUACMKPRFUQW6P5LP7/53%2B%2BIMG_9289.jpg Projects On the third test flight I started trying to push the planes speed capabilities, and at full throttle (which I now know to be around 115kph) I started to get aileron control reversal. Although I was not expecting it, this is something was already used to from previous projects, so I slowed the plane down and landed. In most cases aileron control reversal is caused because when the aileron is deflected upwards to make that wing move down, the wing twists in the opposite direction increasing its AOA. The result is that the wing generates more lift instead of less and the wing moves upward, opposite of what was expected. This was the case in this situation, to solve this problem I laminated the wing with 3M Glass Fibre Tape, this increased the torsional rigidity of the wing and stopped aileron control reversal at high speeds. This was not the perfect solution however because it added 72g to the wing in total, that’s 10% of the weight of the entire plane! In the future I will have to investigate better laminating materials or a way to improve the torsional rigidity another way. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303486675-6ZT0AGFSOVPBCO44XID1/54++IMG_9291.jpg Projects The burnt ESC taken out of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303552246-4XXBAASSVOX7V0CPF46H/55++IMG_9312.jpg Projects New ESC ready to put in. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303575736-NNTBV3TPNRVW8T6QJJMV/56++IMG_9319.jpg Projects Both of the new ESC’s in place. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303633864-X3HX6KZ52XOY6WC4XQ15/58++IMG_9351.jpg Projects GPS for the autopilot mounted on the tail, as far away from the ‘noisy’ video transmitter, control receiver and motors as possible. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303677826-HZC37FTWWWZZNB5KLIG1/60++IMG_9354.jpg Projects New wing connectors for the autopilot. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303701544-7M1MJFE4US1XCQVBID73/61++IMG_9358.jpg Projects Cut a hatch in the wing for the receiver so that I could flash new firmware that had been released since I put it in the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303786747-K32FRPEQKSOCJNSRLNM8/64++IMG_9474.jpg Projects Some messy ceramic capacitors and an inline shottkey diode I added to the video transmitter power supply line to reduce a small amount of interference that was still left in the video downlink. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303729498-M59YS6JDA5TNPZ6GXZ62/62++IMG_9362.jpg Projects Calibrating the ammeter built into the flight controller. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563303754930-W3BE3G73865MZPB4LU57/63++IMG_9369.jpg Projects Flight controller mounted in the fuselage and all wired up. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563651532700-726LMC8516DRA78ZI1L4/01++IMG_9480.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563651586948-RWLTYKGQ5KA5ZVX63XR8/05++IMG_9492.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563651627084-XWJKB36PRXGW6G7AI1EN/08++IMG_9503.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563665419354-IBNFZA7HTZ6SIWDDDSGD/IMG_20190507_194104.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563667994064-XNPJ4JY6BOS55LQBLQVS/002++IMG_9548.jpg Projects The new wing ribs and motor mounts. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668051123-M9DDDEDC71Z3K297CGDN/008++IMG_9607.jpg Projects Wing ribs glued to the carbon with 2-part epoxy resin, I first lightly sanded the carbon parts to help them bond better, which should help with torsional rigidity particularly. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668030633-DSXQMS4N04Y1T2YKH7CD/007++IMG_9606.jpg Projects The first wing ribs glued onto the wing spars, the centre spar is the 8-6mm roll wrapped carbon tube, and the two outside spars are 6-5mm pultruded carbon tubes. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668087629-D301RPWQZOEBKCST1OPJ/009++IMG_9611.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668153525-SPHYEUG7J9SZIA45R032/011++IMG_9616.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668186510-BF831NHCVYYMLHLF6S8Q/012++IMG_9617.jpg Projects I cut this slot in the bottom of the hole for the spar in the motor mount to allow the hole to expand to fit. This turned out to be a problem later because as the hole expanded around the spar the motor angled upwards. to sort this, I had to make shims for the motor mount. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668216412-XC08FPJA09OWDKHCAELF/014++IMG_9651.jpg Projects All the spars and ribs glued together including the outer wooden sections. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668255094-QCRZMA0GOKC2H8PUENNU/016++IMG_9647.jpg Projects Laying out the electronincs on top of the wing to see how well they would fit. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668289386-P6EY277ZVOOPL4EWMCL7/019++IMG_9652.jpg Projects The weight of all the elctronics on the wing, excluding the motors and video transmitter. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668327479-I89V4FYFPW0NEE0MJDK8/020++IMG_9653.jpg Projects Remounting the ESC’s in the same position as in the old wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668350983-ETBCWES2RDBE8UH1P0VF/021++IMG_9657.jpg Projects One of the more minor changes I made was to switch to coaxial cable (from just a normal 30awg wire) for the analogue video transition line between the On Screen Display and the video transmitter. I’m using 50 ohm coaxial cable whereas it should be 75 ohm, but I correctly (it appears) assumed that it doesn’t matter too much in this case. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668380277-JIR10D2XBW0XEV328L0N/022++IMG_9662.jpg Projects Arduino installed right next to the right aileron servo, near the main receiver. This is used to convert the Sbus signal from the receiver into The PWM signal needed to control the flap servos. My code is just using a very simple implementation of the Arduino Futaba Sbus Library. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668411993-8K7HSPWXTCZ3CBPSZUFA/023++IMG_9663.jpg Projects LM7805 Voltage Regulator to step down the battery voltage to the 5V that the flap servos need. Since these servos are smaller and use less current I don’t have to worry about cooling the voltage regulator. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668546049-O6RU03SBSZKKD67FBHI7/027++IMG_9684.jpg Projects Cutout in the foam upper wing skin for the motor mount. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668451897-EHEAB6UN6AMZRM8HAUGC/024++IMG_9670.jpg Projects All of the electonics (except motors) installed in the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668486227-DKPRGOIZRG9HGG6341PS/025++IMG_9680.jpg Projects Motors installed and foam creased, ready to fold over. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668576642-X1I9BXT4QIYA4XFV6DOF/039++IMG_9706.jpg Projects I have carried over putting the expanding foam in the leading edge of the wing from the V1.0 wing. It worked really well and made the leading edge of the V1.0 wing very durable. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668616069-PNZWNNHGEKVWB7KNO4XH/041++IMG_9709.jpg Projects Gluing a coffee stirrer into the trailing edge of the wing by the wing mount to prevent the rubber bands from digging into the wing, as was starting to happen on the V1.0 wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668646778-6MA87E5NAITJXDKO9RAC/042++IMG_9711.jpg Projects New wing next to the old wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668721430-VVG8BGG8P9IBZIDTY20R/045++IMG_9716.jpg Projects I thought I would try using SolarTex Covering Film to cover the wing this time. It’s a type of shrink wrap that has long, natural fibres to increase its strength, it’s better for my use because it weighs less than half that of the glass fibre tape, and from my testing gives the foam the same if not more additional strength. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668752359-YMW1V7ZQVCN3YMX90CCJ/046++IMG_9717.jpg Projects Unfortuanely all of my test pieces have been on flat sheets of foam without holes in, it proved to be much harder covering an already build wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668780251-UYRDO9Q7GHP80ZEXAYEB/047++IMG_9718.jpg Projects Not coming out very well, I couldn’t heat up the covering enough to shrink it before the foam started melting underneath. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668813203-6K7MBICI73NRHXDWB61H/048++IMG_9719.jpg Projects The top side didn’t go much better either, I decided to peal it all off and just leave it mostly uncovered as originally planned. Luckily this little experiment didn’t do much damage to the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668887693-0TRHCY9Z36IO5NUD807C/051++IMG_9728.jpg Projects Flap servo linkage setup with the my 3d printed control horns. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668843998-KQBMFO8QW0H30C3WK13B/049++IMG_9724.jpg Projects The new wing came out 40g lighter than the old wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563668938331-1Y59O9MN7IK6CWHHR7A8/055++IMG_9739.jpg Projects The new wing all done and on the fuselage, ready for the maiden! Unfortunately… https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700021955-DCYMVWCZA90PD3NZCEY7/059++IMG_9755.jpg Projects The 3d printed 2:1 gear ratio for the camera pan and tilt mount that should have allowed for a 360* horizontal view, unfortunately it turns out that the servo only had 160 degrees of rotation. This will have to be redesigned at some point. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700059612-Q6G8GK3K000AI9FXCRB3/061++IMG_9759.jpg Projects Skateboard bearings in use for the output shaft of the Pan gearing, to keep everything sily smooth and durable. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700088344-R1AVWY2Z4XT50YOKRYKF/062++IMG_9760.jpg Projects The top half of the camera pan and tilt system. On the left is the camera lens/sensor, in the middle is the tilt servo, and on the right is the Camera recording/control board. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700111497-GDXQJAACH1UM3WUFUAQ8/063++IMG_9762.jpg Projects 70.5 grams for a (nearly) 360 degree by 90 degree pan and tilt system with a full 1080p HD camera, that also doubles up as an FPV camera isn’t bad in my opinion. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700163300-44UAKLOSOT8Y2LY46IO5/064++IMG_9763.jpg Projects Gluing the bottom half into the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700346732-UIZT4BPONIOTPX9VCE4E/066++IMG_9766.jpg Projects Bottom half glued into the fueslage, with one of the prototype parts on the right of the frame. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700627733-CJ0Y9LUEPJKMO1NYZSIO/071++IMG_9778.jpg Projects Mounts onto the fuselage with a very low profile. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700225021-72V77CCMTPQS5O9YHEYV/065++IMG_9765.jpg Projects Overall extremely happy with how this turned out, it’s the lowest drag design of any pan and tilt system I have seen, and it still maintains a low weight and high simplicity. It looks relatively odd having the point of rotation of the ‘pan plate’ being so far back, but this is so that the camera can look straight down in any direction (other than backwards) which yet again, I haven’t seen from any (top mounted) other design. This also makes the system appear to have lot of backlash since the camera has 5-10mm of backlash, but realistically, only the angle matters and that it roughly constant regardless. I had thought about putting a ‘strake’ on the back to aerodynamically stabilise the pan plate, but in testing there was no problems whatsoever from the get go. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700405546-HD22RAYM6JW71YYIJ2IL/067++IMG_9769.jpg Projects With some of the new parts I was adding I decided to rewire the flight controller. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563745232170-QNID8LER9YPZT6MGWV21/068%2B%2BIMG_9771.jpg Projects I also decided to add a simple power distribution / 5V stepdown board, which just consists of some perf board, a switching 5V regulator and a linear 5V regulator. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563700579830-KG8RXVG9PRA6HATTRS85/069++IMG_9772.jpg Projects Added a video switcher, ready for adding the second camera and second OSD. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563701527846-ZEWP1XZH10OLI5C0DPZK/072++IMG_9780.jpg Projects Finally made a fairing for the nose of the plane, as it turned out the plane was completely fine with no airflow in the fuselage, so I covered it up to lower drag and buffeting. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563701572913-63H2PX9P4CXH2K9F862F/073++IMG_9784.jpg Projects The pan plate is just long enough to clear the nose https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563701681344-NRU3BEPAFF4OJC32Z7DJ/074++IMG_9787.jpg Projects Much more aerodynamic now. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563702975565-CULAA9K4WHYX4PV51KGQ/077++IMG_9794.jpg Projects Second 900MHz receiver being added. The first one has two antennas, so between them both I have all three 90degree polarisations. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563702995840-GO69OWX0IDWL880PR3N7/078++IMG_9795.jpg Projects (Centre of frame) Redundant 2.4GHz receiver being added. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563747189004-PXZCGFP5AH4MJG1Q0PXF/081%2B%2BIMG_9801.jpg Projects Redundant second camera added. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703168431-T7WWCUP8LURMX6TKSAXW/082++IMG_9802.jpg Projects All the wiring on the tail finished and taped over. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703202151-09MPK9NKCQQ8BTBM2E8T/084++IMG_9806.jpg Projects Unfortunately adding the second camera seems the have added these rolling horizontal and vertical lines. I’m guessing that this is due to sync pulse interference, but I’m way out of my depth with analogue video to know whats going on. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703220235-N56KPQTCZDF3KKN0LUXZ/083++IMG_9805.jpg Projects I bought some Low ESR Panasonic FR Series 1000uf Capacitors, I thought they may help with the issue and was wanting a reason to justify getting some nice, expensive low ESR capacitors anyway. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703236115-JI8RQCR7OD6RU5N0XDRO/085++IMG_9810.jpg Projects I added one close to camera on the tail across its power supply lines and it seemed to help a bit, making the lines a little less darker. I didn’t get to find the cause of this problem because it went away the next day without changing anything (as far as I’m aware) and didn’t come back. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703259738-1NDZCKXYLJ2NVNG59QFK/086++IMG_9812.jpg Projects A few days later I also replaced a standard 500uf capacitor with one on the output of the ammeter built into the flight controller. This helped to stabilise the ammeter readings significantly. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703306298-W31BYDMDVT0H7GVYJRBD/091++IMG_9830.jpg Projects Finally making wingtips for the plane, almost 4 months in the making! https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703354643-ILLQUK6JBM8UXCYUY48E/093++IMG_9835.jpg Projects Foreground: after 4 months of hard flying the tail boom came loose and cracked the flimsy foam fairing. I cut it all away and reinforced the tail boom mounting point with 3mm plywood making it rock solid. Background: the blurry wingtip can be seen on its debut, surprisingly it made no difference in flight characteristics, this is the first time I had tried this type of 45* up 45* down wingtip and I think I have misunderstood how/why it works aerodynamically on the latest passenger jets. I will have to investigate further in the future. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703388933-AAV1KGBNSPYHQ7UU69DZ/095++IMG_9922.jpg Projects Installing the second On Screen Display, this is a whole second flight controller with a second GPS, but I’m only using it for the OSD. In the case that my main flight controller fails or main GPS stops working this one should still be fine meaning I will still be able to navigate using GPS. Note this GPS is mounted at 90degrees to the other one, meaning this GPS should keep signal if the plane was upside down for a long period of time. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703426454-GMV26QHN5FSPUM999KTL/099++IMG_9956.jpg Projects Foam fairing for the servo, on this side of the V-tail it also doubles up to cover the secondary 900MHz receiver. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703755675-R72NTWIVKRGLUWX1AQGF/IMG_0021.jpg Projects Weighing the finished fueslage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703781909-3D6G9E6HABG60JG1QIEV/IMG_0022.jpg Projects The fuselage weighs 417g without the camera pod. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703858957-NU4KIVEXL2WUIOQVR4DC/IMG_0020.jpg Projects Camera pod weighs 80g. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703833275-42MYG8GQXFFKVEQ08WRJ/IMG_0024.jpg Projects Wing weighs 529g. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563703810747-IGRWAK3OH9G0PIT21XLP/IMG_0023.jpg Projects Wing being weighed, and another view of the wingtips. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810688063-97ZXV4523UF4XJDH43V4/IMG_20190602_205549.jpg Projects I was flying late in the evening, just after sunset, doing aerobatics and general flight testing of the plane which I had been doing for the last week. The wind was 20 gusting 30 mph and the visibility was low with it being so dark, but it was the only time I was able to fly, with the preparations for D-Day commemorations in Portsmouth meaning that I wasn’t allowed to fly during the day. I was coming into land on a low downwind (I had already lost more height than I wanted on the crosswind to downwind turn), and a large gust of wind rolled the plane violently to the right. I managed to level the wings, but I had lost too much height and the plane hit the ground hard. The plane would have been salvageable if it wasn’t for the strong winds which meant that the plane was potentially flying at >80kph when it hit the ground. This crash was very demotivating as with the new motors, propeller and improved wing tip design (I cut off the top 45 degree plate) I had got the plane down to drawing 5 amps while at a 50kph cruise. This meant that with the hybrid battery pack that I had now finished and proven to provide 16000mAh, the plane would have had a range of 140km. And I figured there was still room to improve. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810907596-IEAS4VD6CN9X0K9ZH0GY/IMG_20190602_210428.jpg Projects The new motors and propellers that I was testing, these were exactly the type of motor I was looking for 6 months ago when I built the first plane. Now, because of the ‘6s battery’ craze with racing quads, this type of motor is being made. I will explain further why these are better in the V2.5 build. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810785661-G2U5ECYLWG9JQBWDHI5Z/IMG_20190602_205910.jpg Projects Front of the fuselage is absolutely destroyed. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810876682-XI3PSW576Q9KPN66J0PU/IMG_20190602_210115.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810827502-11E2OGL4GQN2T1IRC0YK/IMG_20190602_210008.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810940036-VFC1SEMMMLA93WJ2811Y/IMG_20190602_210226.jpg Projects Even the wing skins delaminated from the ribs it was such a violent crash. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563810755865-VGURZHB6WFB5ZI1SR5T1/IMG_20190602_205558.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564137752775-0OD7ZI64Q5GZU294WQX8/IMG_0158.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166322198-NTW2LHUMHR2KXLFKAOPW/Cad+of+Pan+Tilt+Parts.PNG Projects I started off with designing the parts for the new pan and tilt system, while waiting for parts to arrive for the rest of the plane. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166377941-8K3QN2K4Q0SOHP0RLS6V/IMG_0088.jpg Projects Pan servo mounted in the pan tilt system. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166416284-Z3ELBE3BEUSVFTCEDKMI/IMG_0089.jpg Projects New larger driven gear for the 3:1 ratio, becuase of this I removed the other half of the gear to save weight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166457029-KC4AXDSGOZPZ1FKFQ16C/IMG_0091.jpg Projects This shows where the new pivot point is on the pan tilt system, the pivot point is moved 30mm forward, putting it almost in the centre of the pan plate. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166548760-YFD2OK3SBNV5UK05PK9T/IMG_0098.jpg Projects Top view. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564166615725-8SSE26OH22BCPQQ9BMXJ/IMG_0099.jpg Projects Bottom view. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564169176089-N3CNX4QRC2M5ZTW7Q738/IMG_9863.jpg Projects The new pan tilt system weighs 8g less than the old one, thats a 10% decrease in weight, with extra functionality! https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564170818824-FUTKTQB3HS4KF6DUFM9E/IMG_0092.jpg Projects All of the 3D printed and laser cut parts required for the plane. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171301765-4QV5JOP1ZGJCWA22MO3D/IMG_0094.jpg Projects Fuselage coming together. It is a much quicker process now that I’ve laser cut everything. And it even appears that I got all the dimensions right in the designs! https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171120961-RDX6K5JOWCZ262D6HQ0Q/IMG_0093.jpg Projects Tail dry fitted together with new 9mm foam and redesigned plywood reinforcement. Dry fitting did not come back to bite me this time, luckily. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171394788-Q00RX9LRJI2VTCKZSQHF/IMG_0096.jpg Projects Boom mount, particularly showing how the fairing is now structural. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171508036-K5RUY5DC8PJ6BC92PSWH/IMG_0101.jpg Projects Pan and tilt system mounted on the fuselage. This time i have designed it so that it is more easily removable for maintenance. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171562649-5794GLN5119FSC0HHH4G/IMG_0102.jpg Projects Fuselage airframe mostly done. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178452644-F1RXR7LQ3DSL1I5AYWSS/IMG_0152.jpg Projects New cover for the tail electronics, it provides no real advantage over using tape, and probably weighs more, but it definetely makes it looks a bit cooler. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178401998-9G3QWXTAU9BVGZIIC2XM/IMG_0153.jpg Projects Tail finished. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564171772523-O9DZBC1L1VEW0567GICV/IMG_0104.jpg Projects Begining to mount the electronics in the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564177056308-D2I04WY28RUDCCCS3WDB/IMG_0113.jpg Projects Internal structure of the wing glued together. It is all the same as V1.5, except each of the outer wooden sections are 50mm shorter. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564177117539-PU69WICB9JEDGG7UR1KL/IMG_0121.jpg Projects The new V2.0 wing next to the old , torn apart V1.5 wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564182586188-0A02TLXGNJ4F42IDRU43/IMG_0138.jpg Projects Left half of the wing internals. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564182525682-ANXS5QXMG3NSMQ4TCWOS/IMG_0139.jpg Projects Right half of the wing internals. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564177737904-32IEWMIPPY0SVZU8PNM0/IMG_0140.jpg Projects Another view of the inside of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564176925668-YVZCGO147P1HNFR79SUM/IMG_0112.jpg Projects I’ve saved 15g per wing side just by switching from glass fibre tape to SolarTex, and its stronger. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564177919477-M6I0L7MHNFMW7V2F9R67/IMG_0142.jpg Projects Wires exiting the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178158389-L9DKYOSOVANDWGF0DUDF/IMG_0145.jpg Projects Using the expanding foam in the leading edge of the wing for durability, as in V1.5, however cutting back the amount to reduce weight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178113282-XMOIG9MYZ4LV2W6768NH/IMG_0144.jpg Projects Creasing the foam while getting ready to fold over the top wing skin. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178207449-RFQA3NV6RJC6D3D72MKX/IMG_0146.jpg Projects A last look inside the centre section of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178536202-9NGVGWE46X83W8KL26FU/IMG_0149.jpg Projects Laser cut wingtips glued onto the ends of the wings. These are the same design as the final V1.5 wingtips. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178594979-X7TP6S13MMPZ34CPIZYF/IMG_0150.jpg Projects Video transmitter temporarily mounted with tape onto the underside of the wing, so that i can easily swap between video transmitters for comparison. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178321969-D41CHXESU0D8P20TRGF0/IMG_0148.jpg Projects Plane finished and ready for the first flight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178660989-KFCIKS3SUDZVPKQD6HUU/IMG_0147.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1578159035510-U7G28OIS1EE0W346SLVA/IMG_9863+%281%29.jpg Projects 8g weight saving over the V1.5 pan and tilt system, as mentioned earlier. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178824577-S4ZWPLA50E22IZ8ETB77/IMG_9864.jpg Projects 25g weight saving over the V1.5 fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564178875102-8LMM6W6KG1NDIKMZMEG9/IMG_9865.jpg Projects 74g weight saving over the V1.5 wing with the new motors. This number seemed high to me, but I checked, and then checked again. 30g of that saving is the new covering film, and the only other significant difference is that the wingspan is 100mm shorter. I guess having 100mm less foam, 100mm less wire and so on save quite a bit overall? Certainly more that I thought. I was figuring the wing would weigh 40-50g less. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564179440588-YG1DLA1C7D8E59T3GN8E/IMG_0158.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563827619949-AV9RPCMJ8W8XQMEOXMU4/IMG_0173.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563839463278-E3FZU35J1WQR8TLY7Z7S/Capture.PNG Projects I designed my antenna for 868MHz using 0.8mm copper wire, not what is shown here. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563838764416-YDDNOL945NRNCUK9WH8U/moxon915-1.jpg Projects True-Mox antenna by TrueRC, unfortunately they don’t make one for 868mhz, only 915mhz. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829194388-KZPLFVVWK5O0C0E4JS6I/Anetnna+%282%29.jpg Projects V1.0 3d printed antenna former. This first version was based on Pawel Spychalskis’ design https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829267637-W1OP706KDIM3CYN6UDHD/Anetnna+%2810%29.jpg Projects RG402 semiflexible coaxial cable with the inner RP-SMA antenna part about to be soldered on. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829338919-XBU7FX1TDGRG9SLZI46X/Anetnna+%2812%29.jpg Projects RP-SMA antenna soldered onto one end of the cable. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829407307-SQRW5UI26IQY3QXPLLFT/Anetnna+%2815%29.jpg Projects Cable seperated ready to be soldered. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829463528-ZPGPIVV5I9LYV2S4JUTM/Anetnna+%2817%29.jpg Projects Coax cable in place in the V4 3d printed part. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563829575107-JT6HN0FU98LS19AJT1Y9/Anetnna+%2818%29.jpg Projects Driven element soldered and in place, just needs the reflector. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563840173917-15OUX7YZC0SGU5MRDME3/Capture.PNG Projects Test data that I used to tune the antenna, where ‘gap’ is the distance between the driven element and the reflector, and ‘Trim’ is the amount of material trimmed from all 4 ends of the antenna from the arbitrary length that I started at. I decided to go with #20 for my final design. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563840207091-TM04E0622RLLG10KKPAO/IMG_20190131_124319.jpg Projects The SWR Graph for my final antenna. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563830499928-8TGP14F89W01B5FI790K/IMG_0193.JPG Projects Finished antenna. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563889343644-SYYIVLJORWKPUHHJ7V34/Capture.PNG Projects With a 20 turn helical I should get around 18dBi of gain. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563831842668-H9SVPVH6GKW90K9RJEOU/Anetnna+%2821%29.jpg Projects Former for the helical antenna, and formed wire. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563831705218-27159U30HPY0LI9X2XCU/Anetnna+%2822%29.jpg Projects The 3D printed antenna ‘holder’ I designed. Note the join in the middle, this was because the design was too tall to fit on my printer. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563832077849-3V5W6G6UY6F0DCVAWHKX/Anetnna+%2823%29.jpg Projects Ground plane reflector made out of FR4 cut on a bandsaw. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1563832342355-HYBZ3CN87XKJLSKIW2BV/IMG_0179.jpg Projects The final antenna, I modified it to be an 18 turn helical so that I could fit it on my 3D printer in one part, with this change I lose less than 1dBi of gain but get a much nicer looking part that is much sturdier as well. Unfortunately, I made a mistake on the design of this holder, so it’s actually a 17.75 turn helical, although this should have little to no effect on performance. I can’t test the SWR of this antenna accurately using the Network analyser at my university since it is only calibrated up to 3GHz, but for what it’s worth, it said it had an SWR of 1.12 with a centre frequency of 5840MHz. I can however say that from initial tests I seem to get very good range with it having already got ~4km with ground tests compared to less than 250m with the cheap omnidirectional antennas that I have (approximately 1dBi gain) This is particularly impressive because I have got as far as 1.5km with the same cheap omnidirectional antennas when flying the plane, and this was only limited by the spotter being able to see the plane line of sight. This would suggest that with my helical antenna I should be able to get at least 12km when using my helical antenna when the plane is in the air. Hopefully I will be able to test this in the future. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564007605898-GWMY9M03AJJRQMU34J4N/IMG_0194.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564013305231-0JFJGORTPEMJ5IAP1RTM/Circuit+Diagram.PNG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564070983236-SQ4CCQ7ZLXXWH2NLQULG/088++IMG_9821.jpg Projects First I made an Lithium Ion 18650 battery pack using Panasonic NCR18650B cells. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564076826189-UG1GBXV6KRFLEPNJJM58/100++IMG_9959.jpg Projects The total weight of a 3s 3400mAh NCR18650B pack is 30g lighter than a 3s 2200mAh Lithium Polymer battery. (this doesn’t equate exactly due to the slightly lower voltage range of Li-Ions, but is close enough) https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564071083590-CFPFL3FXA3D5OJ5KJMYZ/096++IMG_9948.jpg Projects Two STPS20L15D Schottky Diodes, I’m using these for their low voltage drop of 0.3V at 20A, this is the perfect amount of drop to equalise the battery chemistries, with the current draws that I am expecting. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564071326169-PM55FJU7OSUBTWJJC3XN/097++IMG_9952.jpg Projects The two simple harnesses that I made with the Schottky Diodes to connect my two Lithium Polymer batteries with my two Lithium Ion batteries. In the middle of the hybrid battery project I switched battery connectors, hence the difference in battery connectors between photos. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1564076142304-58V94T3WYK7JGGJW3B72/098++IMG_9954.jpg Projects Both of the wiring harneses plugged into the plane. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1570820400387-SO4HNGFFH4QJXAP3S77A/P7050039.JPG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1570119337891-HXJLVZGMZC1GK0DGPIPF/IMG_8156.JPG Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1570225561303-8LMTQFUVHBMO8MBFAZVG/s-l1600.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574029709234-0TOBA1W5JAJNGFN27BLR/IMG_0047.jpg Projects Motor mount and fuselage sides ready. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574029765706-I4NX8SJIOOFJXOPC3UN8/IMG_0049.jpg Projects A close up of the ‘quick release’ motor mount that I designed for this plane. I figured there was a fair chance that I was going to be burning up motors, and making them easy to replace wasn’t going to be a bad idea. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574029792488-9KIKTAVYOZR4F679BLKA/IMG_0051.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574029844753-JRWHP7E7APMPVKU5FY3V/IMG_0053.jpg Projects The selected batteries being using as a ‘forming jig’ to shape the fuselage around. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030413354-RYWTIPPJY6E45G85LWRK/IMG_0064.jpg Projects Tail cut-out and glued into the rear of the fuse. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030380971-5YNPGSLI8GQ3KNO1SWFQ/IMG_0058.jpg Projects Batteries fitted with the fuselage complete. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574029979600-4E9VULNPRNH4MCEVDHEL/IMG_0073.jpg Projects The basics electronics layout in the wing, note that there is only one aileron servo. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030046587-GREHY1BK8AEO7IVB0RN6/IMG_0078.jpg Projects Series battery connector so that I can use two 3s batteris for better packaging. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030094949-UZVZ9J6FFTG79TDC3MI8/IMG_0079.jpg Projects GPS installed and the wing all wired up - one of the most simple planes I’ve built in a while, electronically. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030250969-ABJ2QF592R05AAC8HCK8/IMG_0080.jpg Projects Wing top side, note there’s only one aileron cut-out. At the speeds this plane will be flying at, it will be near imposible to notice the effects of only having one aileron. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030205170-8GJEPQM47SLGOUULGS62/IMG_0081.jpg Projects Underside of the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030532905-8SSTNMDW5O1A2DNF7AW5/IMG_0087.jpg Projects showing the airfoil of the wing, it came out very well. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030811822-2JYT50FUNHJQAGO3E0K0/IMG_0091.jpg Projects Wing mounted on the plane, sans aileron. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574030846853-BZODRAXWTSMFGYGE8B20/image-asset.jpeg Projects Motor finally wired up and ready for the test flight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1574031172333-BN2PM9DYEDS7Q82ZE4OY/IMG_0111.jpg Projects I actually forgot to take a photo of the plane straight after it was built, so this is after the third flight. By this point, the electronics that were originally left outside the plane for cooling have all been covered, since everything stayed stone cold, and the vertical fin has been chopped down. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691451090-EEXSTZT0AB5HUEI612EJ/IMG_0572.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690573014-07SQJWMHXXSDGDPKQJKB/IMG_0517.jpg Projects 3D printed wing ribs glued to the 6mm square carbon wing Spar https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690602711-03DD9BXV3W13DDSGWZJ6/IMG_0519.jpg Projects The wing spar and ribs glued to the wing skin on the bottom, I would like to say that the wood outer sections are to reduce weight such as in the Long Range FPV Plane V2.0, but it really wasn’t. This is the offcut from the 1m carbon tube that was used with the previous 600mm wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690659769-2EGMI75CUCD6H9RNGE22/IMG_0507.JPG Projects Matek F722 Wing that has been on a diet, inductors and SD card tray have been removed along with some ceramic capacitors. This is not ideal, but the board was already damaged, and I needed to lose weight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690705328-1RU6J7KV58PM9LIOCDEO/IMG_0518.jpg Projects Even more weight shaved off the Matek F722 wing, and the metal casing removed from the BN180 GPS and 30awg silicone wires soldered directly to the pads. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690737789-432F10PV0LPTNI0TE64Q/IMG_0520.jpg Projects Starting to get the electronics in the wing. Notably, I’m using an R9 mini receiver with a very lightweight monopole antenna. the receiver with wires and antenna weighs 1.5 grams. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690779370-QYMA8U7CR9PAU0C7IP0T/IMG_0521.jpg Projects Runcam TX200U VTX Mounted in the wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690803519-74AAZPGFYW1RUPPF4GQ9/IMG_0530.jpg Projects 3D printed template quickly drawn up to cut the sides of the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690831542-PLS9N7XR2MUXJK8B2V9L/IMG_0531.jpg Projects Using the intended batteries as a template to ‘mold’ the fuselage around. Also, the 3D printed quick release motor mount. The fuselage is all 1/8th lite balsa. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690911087-FUQ4S4IT94E3GNY7YKIG/IMG_0539.jpg Projects Fuselage walls glued together, and ESC fitted and glued in place. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690870255-0YD5GWGEAR4VI4MGGMFV/IMG_0534.jpg Projects Adding a ‘ring’ of wood around the outside so that I can sand it back later. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690951067-TX83IJ3BEJXNYELK5QDG/IMG_0541.jpg Projects Tail glued in Place, the horizontal tail was salvaged from the previous plane, and the vertical was my first ever laser cut part on my DIY laser cutter. Both 1/8th balsa https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580690985741-7JVHD05CKLF9W8Z52FMD/IMG_0543.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691025987-VU2W3H6160N2MNJGPW9E/IMG_0548.jpg Projects Battery, ESC and servo wires poking through the underside of the wing, ready to enter the fuselage. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691067842-G8NTTUIY0L3HUO5AZY75/IMG_0552.jpg Projects All the internals of the wing done, and ready to fold over the top wing skin. Also, as with the Long Range FPV Planes, Gorilla Glue is being used along the leading edge for dent protection. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691134126-NEYLUAIC8XGD65T4A58M/IMG_0553.jpg Projects Wing skin folded over, this time I’m using 2mm Depron for my wing skin, with UHU Por used to hold the foam to the internal structure. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691175218-M337JNJSVJDYURYSM9OO/IMG_0557.jpg Projects Underside of the wing. I had run out of 3M Blenderm Tape for the hinges, so for the time being I’m using duct tape. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691229885-DESPH4RGD3ICP9DW6THY/IMG_0558.jpg Projects Wing glued to the fuselage, slightly further back than V1, to aid in achieving CG https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691279122-904QGVZISUNT5WQ73EZM/IMG_0559.jpg Projects Underside of the plane with tail servo and linkage and wires being shown. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691315524-B6AVOKXE0TM620UXRNBC/IMG_0562.jpg Projects Batteries installed in the plane, showing just how tight the fuselage is around the batteries. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580757331793-LWUX5T4TBMUTLCSJUM08/IMG_0577.JPG Projects Fuselage underside sheeting in place, This is actually after the first day of flying, because I forgot to take a photo of it before that. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1580691418309-JA7IY2S9FZ3010VBAKIW/IMG_0572.jpg Projects Plane all finished with the Xing Camo 2207 2450kv motor attached to the quick release mount. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1581514570506-4W2OXZBK25UJ48WUVP8K/IMG_20200205_152902.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582496009080-BJEN2NETNCZALAW1VOX4/IMG_0638.jpg Projects The Fuse and the old wing, ready to strip an still-working components to move over to the new wing. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582496045247-XFJT3F3LUBV07PTH3JQ3/IMG_0641.jpg Projects The rough component layout for the new wing, for some reason this took a very long time trying to get the lateral balence right. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582496072696-TTH5FF70MIFWX6W8RYS4/IMG_0644.jpg Projects The new wiring scheme also saved 2.3g in wire weight. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582496141297-8PWGE653E3W1NN0OK8AB/IMG_0647.jpg Projects The new wing all wired up ready to be closed. Note that all the wires from the fuse had to be connected to the wing before closing it up. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582496179840-BGPWPVH7SMJXZFVKE59B/IMG_0648.jpg Projects The finished plane, ready for its first flight in its new guise. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582836516557-TXO8WNHSFQQWD2CQOQ75/IMG_0683.jpg Projects The motor mount removed and the front of the fuse cleaned up as best I could get it. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582836477145-GN4Y0P09EELYN4BEO8D5/IMG_0682.jpg Projects I cut the 3d printed Polycarbonate motor mount off with a hack saw, and then removed the remainder with acetone. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582837973734-DM9IYKTO4XYVY45M96M3/IMG_0728.jpg Projects Filling in various gaps around the plane with lightweight filler, and then sanding it back flush. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582837836520-S0756G4J6I4I5CPTOD4P/IMG_0720.jpg Projects The new motor mount only weighs 6g and has a much better path for the air coming out of the motor. It does however sacrifice the quick release motor mount, and quite a bit of strength. This was printed out of Polycarbonate filament, 0.4mm thick walls and no infill. The old motor mount weighed 14g. This weight saving was what would allow all of the filler to be added. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582838034726-AMLM8LXA0600M2E9J4AT/IMG_0726.jpg Projects The new motor mount shown, with the new ESC mounting position. Much better. You can also see here the much smoother transition from the fuse to the front of the wing, and from the motor mount to the fuse. Even the ESC has had some gaps around the less heat-generating components filled with the lightweight filler. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582838009087-3YVYDJ7W6DH3CEER6S8G/IMG_0727.jpg Projects Shown here is the new transistion from the rear of the wing to the fuse. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582837897837-1C4AOS2PHJ0ZQKYJAC11/IMG_0725.jpg Projects New camera pod, this has a wedge of foam embedded in it to reduce the weight of the filler even further. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582837932730-WPWR3ULAJXIXVU4S648G/IMG_0729.jpg Projects I’m really very happy with how the camera pod came out, Its a shame the lens is so big, but other than that, its pretty streamlined. https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1582838075424-JWKREHZSS4HOPUKUA9HR/IMG_0733.jpg Projects The final weight came in 2.7g under the 250g weight goal, that sounds to me like just enough weight spare to add some visibility-aiding colour! https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926092284-81GHV85LF3BT61NJQUB5/IMG_9864.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926142821-DNY9X7GO9TQTADZ0YRI2/IMG_9874.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926185530-04QITJQCSYPFWKX76BFR/IMG_9887.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926240006-C648YMJGQO0AEXQ8EH2Y/IMG_9905.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926861477-BA2MFIYMVA9MHCLQALF6/IMG_9916.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583926896008-AU3X4TXVSC8P4YKEUYU6/IMG_9918.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583927043160-8E2SGJ4P1BI07ZAIDR2I/IMG_9971.jpg Projects 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https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367103039-WZJ5DIZZLOY8L2N9WGBN/IMG_0984.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367128323-DWCQEG3FOBKIR17ZYETR/IMG_0988.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367156662-PCNCGWMOL6PJL037QO9Z/IMG_0990.jpg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367177622-GX93IOZPZV8OSNSTC0VM/image-asset.jpeg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367200013-KRBUHG3TYU1ENP7B62KO/image-asset.jpeg Projects https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1586367214065-6424740XH36G6RZ7I50H/image-asset.jpeg Projects https://lukeattubato.com/photography daily 0.75 2020-07-23 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573588281086-8UBPCHPQYBO22VHAF4BJ/Edited+-IMG_0068-HDR.jpg Photography https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573587691584-29DS737LGA6BFRTF40X2/IMG_5227.JPG Photography https://lukeattubato.com/influences daily 0.75 2020-03-10 https://lukeattubato.com/influences/jase-dussia monthly 0.5 2020-03-10 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583798675291-CW3QTMMWNRQXTMP8V2PX/maxresdefault.jpg Influences - Jase Dussia I first found Jase Dussia in ~2014 as I started getting into 3d flying, I loved his flying stlye and he was imeditaly one of my favourite pilots. I was lucky enough to see him fly at Western Park in 2018 and 2019, and I hope to see him fly again this year. Mid way through 2019, I finally found an 48” edge 540 demonstrator for sale for a reasonable price, this is the 48” version of the plane that he flew for the 2014 season (pictured), I had to buy it. It was my first ‘propper’ 3DXA plane, a significant investment and I’m happy to report that it is still in one piece (just) and I still fly it frequently. https://lukeattubato.com/influences/ran-d-st-clair monthly 0.5 2020-03-10 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583799081558-9B3IY137018DEOPQB6D7/maxresdefault+%281%29.jpg Influences - Ran D. St. Clair https://lukeattubato.com/influences/ave monthly 0.5 2020-03-10 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1583798440614-PNQT4B865DCE1S1Q9KFE/wNUi0pld7eIP0tINtUdZrovpaRj.jpg Influences - AvE AvE Is a YouTube Channel mostly based on machine work and building, what I can best describe as, interesting things. This channel is not about anything particular, and is in many ways a comedy ‘show’ at heart, but also covers many very adavanced electronic, mechanical and thermodynamic theory in an aproachable way. This channel was a big motivation for me making my laser cutter (page coming soon), and although it is terrible if you want to find specific information, you alwasy come away having learnt something. https://lukeattubato.com/influences/daniel-riley-aka-rctestflight monthly 0.5 2019-11-15 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573771250258-MKEH5D2S4553B4KOV2XQ/maxresdefault.jpg Influences - Daniel Riley AKA rctestflight https://lukeattubato.com/influences/peter-sripol-aka-foamandtape monthly 0.5 2019-11-14 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573769752214-Y4I7KK0DNBM2EGXDVPEA/image-asset.jpeg Influences - Peter Sripol AKA FoamAndTape https://lukeattubato.com/influences/flitetest monthly 0.5 2019-11-14 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573768855196-Z0O9VQIYWG5SLXEN86LX/0caee706365f79dca51f6c8c7cf1e35c_c9fc8044-90ea-40d9-bc99-1c38ec3889e5.jpg Influences - FliteTest https://lukeattubato.com/influences/mark-griffith-aka-rchacker monthly 0.5 2019-11-14 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573766763878-A2I4TPTOVODGQHKPE5F2/mqdefault.jpg Influences - Mark Griffith - AKA RCHacker https://lukeattubato.com/influences/arron-bates monthly 0.5 2019-11-14 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573764943018-INMEOYP1XORPLY09KGEG/thumb-badger1.jpg Influences - Arron Bates https://lukeattubato.com/influences/david-windestl monthly 0.5 2019-11-15 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1573805985919-6WISQ81TIVLT49M3MCB9/Capture.PNG Influences - David Windestål https://lukeattubato.com/about daily 0.75 2019-07-27 https://images.squarespace-cdn.com/content/v1/5cc1a8e4aadd345c914c694e/1556196071715-P03L4V972QO7L2UTV54E/C7BD7FF4-C214-4FD7-B909-0965E8655719.jpg About https://lukeattubato.com/contact daily 0.75 2019-10-20