Was getting annoyed by the stupidly heavy frame of the Scorpion Y650 which is made of thick fibreglass sheets (available from Hobbyking).  With the GoPro sitting on the camera gimbal and a 4S 3000mAh battery I was only getting 6-7 min flying time.  

Had a look at the price of CF sheets and CF 450 size heli tail booms and it looked like an affordable project to design and build a hexacopter from scratch.  Above is the basic design and below is the frame plates assembled with the CF booms and aluminium boom holders.



 

www.multiwiicopter.comin Queensland sell a clear dome with a 100mm diameter which will fit nicely over the electronics.

Just this portion of the frame is incredibly light.  I'm quite hopeful that I will get much longer flight times than the Y6 with this design.  Sheered one of the bolts in the process so will need to pull it all apart and try to get the remaining bolt out.

 

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Comment by Rob_Lefebvre on August 31, 2012 at 6:19am

Nice looking so far.  How did you cut the CF plate?

Comment by John Moore on August 31, 2012 at 6:29am

What motors are you using?

Comment by John Grouse on September 2, 2012 at 10:27pm

I'm making good use of my Dremel cutting disks.  The ones that are designed to cut metal cut through the CF like butter.  Just leave a 1mm gap outside the template edge when you cut the shape out and then refine it to the template edge with the Dremel sanding tubes.  Finish of with a fine flat file.  For holes just tap an indent dead centre with a sharp point and then use a drill press with sharp bits at the desired diameter.  I have the Dremel drill press to do this.  Yes, I love my Dremel, and if I keep talking like this then they should send me some freebie's.

The motors are DT750's.  Cheap and do the job nicely.  Just wish Hobbyking would sell replacement motor shafts.  Still waiting for a bunch for three blade GWS props to arrive to see how they perform with 4S and the DT750's.

 

Comment by John Grouse on September 2, 2012 at 10:32pm

This is the lightweight CF motor mount I designed.  Will use grommets below the motor to see if they reduce any residual vibration from travelling down the CF tubes.  CF is not the best for reducing vibrations, however it does cut the weight down without loosing strength.

Comment by John Grouse on September 7, 2012 at 9:24pm

GPS Support Frame made from PCB board. Left the copper on the surface to allow me to solder the legs on and use it as an RF shield (ground legs to battery GND).

Clear dome from MultiWiiCopter store.

If I find that the grounded copper surfaces interfere with the GPS I will etch off the copper.

Comment by John Grouse on September 11, 2012 at 7:17pm

Dome assembled.  The inner diameter of the clear dome was smaller than predicted and the Flyduino OSD board above the MultiWii board was wider than expected (arrived in the post today).  As a result I had to cut into the GPS support stands to give it the clearance it needed.  New MultiWiiCopter GPS/Mag board foam taped to the top of the support.  Just need to spend a day unsoldering ESC's and resoldering the new lengths of wire and then connecting it all up.

Comment by John Grouse on October 1, 2012 at 1:43am

Comment by John Grouse on October 1, 2012 at 1:52am

DT750's and Plush 18A ESC's mounted and wired up.

GoPro camera mount/battery vibration isolating board connected via silicone tubing and cable ties (AKA Tricopter V2.5 method).  Ply board is the only non-CF part of the frame.  Silicone grommets between the motor mounting points and the motor does seem to make a significant difference to the amount of vibration which makes it to the centre hub. 

Comment by John Grouse on October 1, 2012 at 1:52am

Comment by John Grouse on October 1, 2012 at 5:13am
Also tried a GWS 3 blalde 9050 prop on the Dt750 with a 4S lipo and it felt like half the thrust of the 1047 SF props. They are probably better suited to 1000kv motors or faster. Might also test 1147 SF props some time soon to see how they perform.

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