I've been throwing around a few ideas for a hexacopter frame and have settled on a aluminum arm and fiberglass plate sandwich type frame (is there a more technical term for it?). The goal is to carry a digital SLR for aerial photography, though I'll work out the camera bits after I get past the basics of just getting it flying. From prop tip to prop tip it will be about 42 inches. The two plates in the middle are about 11.5 inches diameter and will be cut from 1/8th inch thick G10 fiberglass. The aluminum arms are 1 inch with a roughly 1/20th inch thick wall. The props will be 12 inches by 3.8 pitch.
The blue boxes under the arms are the batteries, the red boxes on the fiberglass plate are the speed controllers, the three boxes in the middle are the APM, GPS, and receiver. Bolts will hold the plates and arms together and other items will be double sided tape and probably Velcro for the batteries.
The machine to cut the fiberglass should be functional in a week or two at which point I'll be finalizing the design and cutting out the parts. If anyone is interested I'll document that process (tool selection, creating the code, etc.). Until next time everybody have a good one!