Flyscreen quadcopter

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Published on July 1, 2012

Description

This is a quadcopter design that uses the folded aluminium bars from a fly screen as the arm struts.

Note that the motor mounts are designed for a spacing of 42mm diagonally between the motor mounting bolts. This is parametrically adjustable.

A bill of materials for my build is available here:
docs.google.com/spreadsheet/ccc?key=0Aq6iGQSKjhLXdEZ6RmtVU3BITUVkczgyS0 N6aTFQbWc

Total weight is 906 grams, with a 2200mAH li-po battery. I have 400 grams of steel strapped to the bottom as a dead weight. It can fly for about five minutes with that load.

Explaination video:
youtube.com/watch?v=9QZtf85m5vY
Action video:
youtube.com/watch?v=VrC8AcyuGwY

For more up-to-date, but less-documented parts, I'm hosting the scad files here: github.com/tjhowse/quad

Instructions

Print one hub piece and four each of the other pieces. I suggest you print a few spare legs as they will break upon a rough landing. This is by design, to absorb a bit of the impact.

Cut four lengths of flyscreen frame bar. I used 200mm lengths, and this is slightly too small for 9 inch props. I apologise for mixing units there, but propeller dimensions are measured in inches, :(.

Fit the motor mounts onto the ends of the rods, making sure to get the polarity right. Make sure you really hammer them on. Measure the length of your arm to make sure it's fully seated into the mount. If you're feeling uncertain about the fit, put a M3x20 screw into the screwhole in the end to lock it in. If you're still feeling unsure, hammer in one of the hub_junction_channel() pieces too.

Slip the sleeves over the other ends of the arm, sliding them down the arm about 20mm. They may require some persuasion. Attach the four arms to the hub, then slide the sleeves back inwards towards the hub. Insert the hub_junction_channel pieces into the channel and hammer them inwards to lock it all together.

Clip the leg pieces onto the arms, near the end.

Done! Your quadcopter frame is complete. Attach motors, electronics and props!

Please note that quadcopters are inherently dangerous pieces of equipment. Please be thorough in your testing with props off to get your directions of spin and calibration sorted out. Having your legs cut to ribbons by a rogue quadcopter is nobody's idea of fun.
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