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Old Jun 21, 2013, 12:14 PM
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Croatia
Joined Nov 2009
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Build Log
Full Carbon Molded DeX Quad

since winter ended I didn't have a lot of flying so I kinda forgot about the fun side of this hobby

and that has to change I need some more "me" time so I decided to make myself a new quad

I will enjoy the whole process from scratch and I'll make a lot of pictures during...



model that I have chosen for this is full carbon DeX 50cm Quad but I shortened tubes from 10cm to 9cm so that the model will have
440mm from motor shaft to opposite motor shaft instead of 460mm and the difference is barely visible




except that model is standard full carbon version with with two red motor mounts.... and the empty frame weight is 202 grams






X quad configuration is something new for me so far I've always flown + configuration but it's time for change


motors I choose for this build are as usual: http://www.hobbyking.com/hobbyking/s...idproduct=7520
they are on backorder for some time now... and "unfortunately" I do not have 4 extra new motors.... only 2....
so I'll have to make 4 motors from scratch(broken motors) and so far I've broken a lot of these motors especially with DeX mini quad so that this will not be a problem




original 2205C motor has 19 turn with 3x 0.16mm wires in parallel
I would like to put 17 turns on my motors with one wire thick as possible
I am sure that I don't have such a wire so I'll spend a day in trying different kinds of wires and getting a right wire...






For ESC's I will use as always 10A turnigy with SimonK firmw from one broken hex, they look bad on the photo but they just need a little cleaning and changing a wire or two



just a thought... I would like to try 3D SimonK option
at the moment I don't know where that thought will lead but we'll see along the way
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Old Jun 21, 2013, 01:42 PM
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United States, OR, Cornelius
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Beautiful! You make these frames yourself?
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Old Jun 21, 2013, 04:04 PM
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Originally Posted by Greiswig View Post
Beautiful! You make these frames yourself?
Thanks!
yes, I'm making these frames....they are all handmade
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Old Jun 21, 2013, 04:18 PM
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I found the wire for motors, old stepper motor had inside just what I needed...
wire is 0.35mm thick and I can squeeze the maximum of 18 turns but I think I will put only 17 turns as I planned....





Now I just need to rewind all motors



Some rotors are more round and some are less round
but in the end all 4 are spinning without touching the stator...
and I think that's the only thing that counts
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Last edited by DeXX; Jun 22, 2013 at 06:25 PM.
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Old Jun 21, 2013, 05:25 PM
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United States, OR, Cornelius
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Originally Posted by DeXX View Post
Thanks!
yes, I'm making these frames....they are all handmade
Figure out how to make these at a reasonable cost, and you could have a business! Especially with this one, where a person could customize the arm length.

Have you thought about perhaps incorporating keyways to keep the arms properly lined up? Probably not, since this is for your use, but if you manufactured them, that would be a nice thing.

Very tasteful, probably pretty light and strong, too. Really nice design. Subscribed...
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Old Jun 22, 2013, 06:12 PM
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Quote:
Originally Posted by Greiswig View Post
Figure out how to make these at a reasonable cost, and you could have a business! Especially with this one, where a person could customize the arm length.

Have you thought about perhaps incorporating keyways to keep the arms properly lined up? Probably not, since this is for your use, but if you manufactured them, that would be a nice thing.

Very tasteful, probably pretty light and strong, too. Really nice design. Subscribed...
Thanks again!

I already produce these models for a while.... but production is very limited because of the way and the time of making...

so that they are kind of under the radar I guess

weight of the carbon model from photos here is 202g and strength is exaggerated....
I have not managed to break the glass version so far and this CF version is even stronger
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Old Jun 22, 2013, 06:32 PM
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3 done one to go... slowly but...

picture shows original 2205C windings (19 turns of 3x 0,16mm wire) vs my 18 turns of one 0,35mm wire

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Old Jun 22, 2013, 06:44 PM
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Hawaii
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Damn! Not only do you make a bunch of nice frames, you can do some man knitting also!!! Good job and very pretty.
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Old Jun 22, 2013, 06:54 PM
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Originally Posted by DeXX View Post
3 done one to go... slowly but...

picture shows original 2205C windings (19 turns of 3x 0,16mm wire) vs my 18 turns of one 0,35mm wire

Hello Denis,

You are very "brave" to start to build new motors

I start to assemble my DEX quad, there is a builing log :
http://www.rcgroups.com/forums/showthread.php?t=1917142

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Old Jun 22, 2013, 07:05 PM
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Originally Posted by SeismicCWave View Post
Damn! Not only do you make a bunch of nice frames, you can do some man knitting also!!! Good job and very pretty.
thanks,

I love man knitting! ... never thought I'd say this

but this build log is a relaxation for me and my mission is to do as much as I can by myself
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Old Jun 22, 2013, 07:25 PM
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Originally Posted by Stefan1204 View Post
Hello Denis,

You are very "brave" to start to build new motors

I start to assemble my DEX quad, there is a builing log :
http://www.rcgroups.com/forums/showthread.php?t=1917142


yes, yes I even thought to burn some FET's "accidentally" so I can practice some soldering
Tomorrow I will try "new" motors and make a log of Amps, thrust....
I have some feeling that I'll need a bigger ESC's



I will definitely follow your build
wow some hi end motor mounting solution you got there, NICE!!
so I guess it will be only a pleasure to see your further progress
thanks for the link!
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Old Jun 23, 2013, 01:36 PM
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I have tested "new" modified 2205C motors today

I used:
battery 3S 2200mAh turnigy 40C
prop 8040 GWS DD
12A ESC with SimonK


I gave up on 10A turnigy ESC's for this build because I saw that the original 2205C motors draw 10A....
so instead I dug out 12A ESC's....

current drawn by motors is over 12A but this is not a problem because ESC's maintain a reasonable temperature during...

The bigger problem are the modified motors....
first of all they are very powerful, 750g of thrust and weight only 25g cann't be better....

The only problem is that the motor temperature is quite high and the burning smell is starting to feel after 30 seconds at full throttle
but...it's just a smell and motor windings doesn't change color which is great

motor was tested as a pusher... so I hope when motors will be on the model and in the air the temperature will be bearable....

or the worst thing that can happen in the end is that I will not be able to fly at full throttle longer than 30s... and I think I could live with that...


I aim for a final weight of between 650g and 700g...
model will be on "fresh" start battery power of 700W and I like the numbers so far...


Charts of 2205C Amps and Watts




.
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Old Jun 24, 2013, 06:43 PM
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all 4 motors are finished and ready for installation...





another thing .... I change the shaft immediately on all of these motors
original shaft is great for SF prop type but too short fot GWS style DD props I use...
so for DD props it is necessary to extend the shaft for a couple of millimeters to gain proper centering



original shaft and the extended one for DD props

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Last edited by DeXX; Jun 25, 2013 at 04:22 PM.
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Old Jun 24, 2013, 07:12 PM
WZ9V (formerly KK4RLD)
Joined Jan 2007
452 Posts
That frame is really cool.
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Old Jun 25, 2013, 04:45 PM
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some of the ball bearings were in very bad condition so I replaced what was needed




The next thing was motors mounting ...




each motor mount has in the middle small but under light visible dot representing the middle of the motor mount



I've marked and made holes



big dent in the middle is due to the shaft and C clip



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