Moving

Message from the guy behind the pencil: Dear Reader, I'm about to move across the country for work. I've disassembled my computer equipment including the scanner and will not be able to post anything in the coming week or two (on laptop right now). Once I'm set up, I will resume blogging. I will miss it. But believe me, the story continues to evolve in my mind. Stay tuned! This thing will fly! Best, Axel

SUMMER BREAK

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Flashback

Rewinding real quick to where the center-of-gravity (CG) problem was fixed. This is what happened back then and how the CG was brought under control. Next steps will be to come up with some electronics, software, and controls. Thinking about it.

ROTFL!

Pulled a late shift to get some stuff done while I can. You never know how busy the times ahead will be. After gluing the last batteries in place and feeding the wires through to the end, I let the glue dry over night. Then assembled to the blades to the head and bolted the close-out plates on. Three bolts each suffice. The rotor head is fixed to the e-motor shaft, which is a tailor-rolled sandwich tube for optimal torsion stiffness. The sandwich material enables feeding the positive and negative sides of the battery down to the e-motor. Connection established. Finally, big step! Got the main rotor onto the e-motor shaft. Now I'm tired...

Tile

Not quite there yet, it really seems like helicopter manufacturing takes longer than you think. At least the batteries are now attached and the three rotor blades take shape.

Finally

Today, the profiles (leading & trailing edges, main spars) arrived, as well as the batteries. The next steps will be assembling the aluminum profiles to the end plates and then applying a process called structural bonding (superglue, blue glue, or similar) to establish a structurally sound connection between batteries and profiles. Batteries do tend to emit heat during operation, which I will counteract by naturally air-cooling them.

Nervous

Getting ready to put the order in for the LiPo batteries. After confirming the size, weight, and capacity, I think I will be fine with 336 batteries. I will order 360 anyway, just in case. Plus changing the BOM will require so much effort. I'm an engineer not a paper-shuffler. Also got some drawings for the leading edge, spar, and trailing edge. End plates are necessary too. Plus 9 bolts to fix the end plates to the structural profiles. Stuff starts to come together.

Sub-Assembly BOM

With the CG under control for now, it's time to start thinking about the rotor assembly. Since it's always good to think before taking action, I made up a bill-of-material for the main rotor assembly. I also made a few first sketches to lay out the overall rotor design. Stay tuned for updates.