EasyStar Upgrade 1: Chassis modifications

Having previous kit I want to use the EasyStar in standard trim was not gonna cut it so modifications were needed. I will document each modification in single posts (hopefully) so others know what not to do.

The chassis/airframe holds the majority of the parts so that is obviously the main focus of my effort. To go into the chassis I have a Hacker A30-16M motor, an eTronix 40A ESC, a 2200mAH 3S LiPO, a Futaba R617FS receiver, rudder servo and all the cables.

My first problem was the chassis being glued. If you cannot reach it you cannot fix/replace it. Neodynium magnets are mentally strong and the chassis has plenty of mounting points for glue so why not "convert" them to magnet holes. Using a drill bit of the appropriate size I purchased against the foam to leave a visible mark then with a scapel (yes a surgical scapel, exacto knife will do though) I simply cut along the line and poked out the foam in the middle. Picture below shows first few holes done and chassis cuts for battery and ESC.

Edit: Picture is of completed magnet installation not build installation (2 magnets)

The magnets are from eMagnets in the UK. I bought two sizes: 10mm dia x 5mm depth and 15mm dia x 5mm depth. They worked well installed like this for quite a while only the heavy landings mad the airframe move even in the slightest.

In the mean time I have done some more fiddling thanks to others on this forum.

The ESC being there is NOT good. The ESC needs airflow so you can stick it out the bottom or side or top (as I have now done). I have used a RAM chip cooler with some thermal adhesive on the bare metal cooler to keep temps extra low. Also my engine while being powerful needed more RPM so I've lost 200w and gained 1700kV and its much more spirited. I am also making the final preparations to epoxy the airframe together. I have shifted everything (except the telemetry) for better CoG but am checking everything fits together closed before I actually seal it up.

I'll put up a blog post showing the new layout soon.

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Comments

Ritchie March 4, 2011 at 5:47pm

I used the magnets but with my new setup its all glued up. Old way was fine but when you put 140g of lead in the front to balance it things probably aren't perfect :D

Now the setup is almost perfect with 0g of lead
Samuel Rosenstein March 4, 2011 at 3:17pm

Another question...how do you keep the tail on?? Do you use magnets for the too, or did you just glue it to only one side of the plane like the motor?
Thanks,
Sam
Ritchie February 23, 2011 at 6:04pm

Yeh its fine. Human knowledge is for the world. Be warned I took my ESC out because even 30 seconds at WOT made the foam expand with heat so a full flight would be melting country.
Samuel Rosenstein February 23, 2011 at 3:07pm

Nice, thanks for the fast response. I'm hoping to add in cooling air intakes for my ESC because I do want to mount it inside of the plane. I'm hoping to make an instructable (and a blog here) with all of the information that I have gotten from people on DIY drones, would it be ok if I used some of the info that I have gotten from your blog posts? Don't worry...I'll credit you :)
Thanks,
Sam
Ritchie February 23, 2011 at 3:01pm

The magnets are from eMagnets in the UK. I bought two sizes: 10mm dia x 5mm depth and 15mm dia x 5mm depth. They worked well installed like this for quite a while only the heavy landings mad the airframe move even in the slightest.

In the mean time I have done some more fiddling thanks to others on this forum.

The ESC being there is NOT good. The ESC needs airflow so you can stick it out the bottom or side or top (as I have now done). I have used a RAM chip cooler with some thermal adhesive on the bare metal cooler to keep temps extra low. Also my engine while being powerful needed more RPM so I've lost 200w and gained 1700kV and its much more spirited. I am also making the final preparations to epoxy the airframe together. I have shifted everything (except the telemetry) for better CoG but am checking everything fits together closed before I actually seal it up.

I'll put up a blog post showing the new layout soon.
Samuel Rosenstein February 23, 2011 at 12:57pm

Nice...I just got my easystar and thought about doing this. Where did you get your magnets?? What size did you use (including the ones for the wings)? Did you cut any air-flow slots for the motor controller? Thanks for all the help and insight! Ohhhh....and awesome blog :)

Sam R.
Ritchie September 3, 2010 at 4:27am

No. Magnets can be used to remove interference around wires and have little effect on transmission or reception as only their metal content is relevant.
Raytrace Nomad September 3, 2010 at 12:41am

is so magnets affect the rc / or video tx ?
Ritchie September 2, 2010 at 7:30am

Thank you TCIII, ordered. Any pics install wise? I'll do a post for my install.
Admin

Thomas J Coyle III September 2, 2010 at 5:21am

Ritchie,

I would recommend the use of carbon fiber tubes (I used 6mm dia tubes) in the nose, wing mount shoulder, and the tail to help strengthen the Elapor foam fuse. It has worked for me keeping the EZ* intact in some minor crashes that would have cracked the Elapor.

Regards,
TCIII

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