2022-03-07     Unsanctioned-1         Build # 13              Last Post                   My Journal             
   
The Unsanctioned-1 is build #13 and is intended to be a sub-250 gram 5 inch endurance quad.

In my opinion, it is essentially not possible to achieve the same performance in a 5 inch sub-250 
gram quad as has been expected from a conventional 5 inch ACRO, Free Style, or Racer. First,
the size motors required to get that type of performance are simply too heavy. Plus, if you want to 
run a 6S battery that just pushes the weight over even further. In the 5 inch size, a sub-250 gram
build will just NOT be a high performance quad.

Consequently, any sub-250 gram 5 inch quad will essentially be an endurance craft and perhaps 
long range. With this premise, I have selected components biased towards smooth cruising at 
altitude and NOT towards extreme acceleration NOR “hi-performance”. This is a cruiser, NOT 
a stunt quad. The quad will be fitted with the BrotherHobby 1504.5 3950KV motors which have
worked quite successfully on a 4 inch build. In my opinion, they will provide the flight characteristics 
that I desire.

I have acquired a previously untested prototype frame that is still in development. 


____________  PARTS LIST ____________ 

Frame:            Untested Developmental Prototype
Cam Brace:      Armattan Tadpole Cam Braces  
FC:                 HIFIONRC F7 AIO 25A         <---{ I am not sure this is still available}          
Motors:           BrotherHobby 1504.5 3950KV                                    
VTX:               Panda Nano 16x16 VT5X
VTX Antenna:  VAX Minion Pro                                            
Camera:          Foxeer Razer Nano 1200 TVL                                         
Rx Receiver:    FrSky XM+  {will wire as SBUS}
RX Antenna:    Included with RX Receiver                      
GPS:               Matek M8Q-5883                                                             
Capacitor:        Panasonic 1000uf 35v

TPU Parts:       Custom GPS holder and custom receiver antenna holder.

NOTE:  All of the parts I had in my parts bin except for the frame and TPU parts.


More details regarding the frame, including pictures, will be added later.

The BUILD continues:
 
Essentially, the electronics package is made up of my standard components. In fact, I already had
all of the components in the parts bin. As such, it follows most of my previous builds except that I
am soldering the motor wires directly to the FC rather than using servo connectors; my norm.
 
In my recent builds, I have “split” the GPS connection into two parts 
which are on separate connectors:

1) the DATA signal pair and
2) the power source pair ( +5 Volt and GND)
 
This method allows connecting an external power source (battery) directly to the GPS without 
supplying power to the FC board and consequently the VTX. The purpose is to allow the GPS 
plenty of time to acquire satellite Fix without overheating the VTX or other components.
 
All of the soldering was performed on the bench rather than in the frame. All parts and 
connections were tested during the process. The FC was also configured during this process. 
The entire electrical system is a complete and fully connected “package” outside of the frame. 
With everything tested, the package was installed in the frame. The entire package including 
motors can readily be replaced or moved to another frame.
 
Installing the electrical package onto the frame was straight forward. Having allowed plenty 
of extra wire for most of the components and using the motors as they came ( I did not cut 
them), it was a bit of a tedious endeavor to get everything “tucked in” and wrapped. I used 
cloth tape rather than zip ties to hold things in place. The 1000uf 35V capacitor was placed 
in the void between the tail of the frame and the GPS. The XM+ receiver was mounted on 
top of the capacitor. The 16x16 VTX was mounted on standoff columns in the rear position 
of the frame. All bolts used in the frame assembly are stainless steel. The motor mount 
bolts are steel, but not stainless steel.
 
Since I like the looks of aluminum camera cages, I used Armattan Tadpole cam braces for 
mounting the camera; my standard Foxeer Razer Nano 1200TVL camera. These braces 
replace the front two standoff columns.

There was nothing special about the actual build process as it was almost identical to many 
of my other builds. The 26x26 whoop format AIO boards are my FC boards of choice. Plus, 
I have wired several of the HIFIONRC F7 AIO FC boards in the past. Since they wire the same,
the pictures are also pretty much the same. I will link some:     

                                          HIFIONRC F7 45A AIO in the Ronin-MK1 ONE.
                                         HIFIONRC F7 AIO wiring diagram of the Quest250-LR.


One thing that I did different was to raise the left front and right rear motor a few millimeters
in order to run 5125 props which are actually longer than 5 inch. I have seen this done, but 
this is the first time that I have actually tried it. 

The final dry weight of the craft ended up at 155.9 grams which is more than I had estimated, but then that 
is about my norm. All of my builds seem to end up a bit heavier than I estimated. At 156 grams, that leaves 
93 grams for all payload including battery and any "extra" cameras. Since I don't use action cams, it is all for 
the battery. Even so, the GNB 3S 1100 mAh 67-74 gram battery is the largest 3S pack that can be used 
in order stay sub-250.  4S 650 mAh 69-74 gram battery is the largest viable 4S pack. That is the battery limit 
plain and simple. By the way the 3S 1100 mAh has more Watt Hour energy than the 4S 650 mAh and will
provide a longer Fly Time. Since this is the objective, the 3S 1100 mAh battery is the largest "Energy" battery.






 





Regarding potential battery options see My Journal Post # 164.

The Unsanctioned-1 is ALIVE see My Journal Post # 167.

It’s been a while since I’ve seen a build thread by you. I’m looking forward to following along. I’d love to see a picture of the frame (as well as the rest of the build as it comes along).

I’m a big fan of parts bin builds.

Good call on direct soldering the motor wires, servo connectors can’t safely handle the amperage those motors can pull.

Hi Lemony,

Yes, it has been a while...like 9 months or so. MY, how time flies when you are building a house.

Actually, the Unsanctioned-1 build is complete; it was built, tested, and had its maiden flight 
before this thread was started. I will be adding pictures of the build to some of these posts as
we go along.

At this point, I am not disclosing the frame details, but that will come in time along with more
pictures...specifically of the frame.

Regarding the servo connectors...I have used them many times in the past, even with these
motors, with no problems or issues. What I like about them is the ability to swap a whole set
of motors without dismantling the quad or trying to solder the FC while mounted {which I try
not to do}. Also, originally, I didn't know about BLHeli for reversing motor directions so I would 
just unplug the connector, flip it, and plug it back in. Fast and easy. Never had an issue with the
servo connectors.  Also, I am forever an experimenter and I have a habit of swapping parts. 
For example, I wire all my Rx Receivers for SBUS so that I can easily swap an XM+ for an R9...
or...just "hop" an R9 receiver from quad to quad for longer range testing.  

Anyway, for this build, I didn't want the extra 8-9 grams or so that the connectors weigh.

Keep in mind that I will be updating Post #1, #2, #5 as we go. Mostly, pictures. 

TESTING:
 
Initial Test Flights
 
With the assembly complete, a hover test flight was performed. The flight was very smooth and
responded well to the controls.

2022-03-06    Maiden Flight at a local park.    Also see  My Journal Post # 168

The Unsanctioned-1 is suited up with a GNB 3S 1100 mAh 67 gram battery.

It was a windy day with wind speed in excess of 15 mph, but since this is a 5 inch we decided
to give it a flight anyway. Standard take off. The Unsanctioned-1 is pretty smooth and stable
considering the windy conditions. This park has a pretty small area of about 100-120 meters 
in both length and width. It is almost like flying in a circle. The drive train has plenty of power
and I am flying at about 15-20 percent throttle most of the time. A pretty uneventful flight that
lasted for more than 9 minutes. 

Since I had not calibrated the battery, I ran out of battery without realizing it. When I did, I
turned around for "home", but tumbled out of the sky from an altitude of about 20 meters onto
short cut turf. Basically no cushion from the hard ground. It looked ok at the field. 

Upon returning home and taking a closer inspection, I noticed that the left front arm was bent
back. Upon removing the front arm pair, I noticed that the arm was actually broken. 

      This information was relayed back to the developer for consideration of making
      a design change to provide additional strength in that area of the arm. 

      When working with a prototype, part of the objective is to determine strengths
      and weaknesses which can then be corrected prior to production.

On the positive side, I believe that I can repair the arm to an operational condition.

Aside from the crash, I view it as quite a successful flight. The frame handled quite well in the air.
In my opinion, the 1504.5 motors are pretty much optimal for a build of this caliber. Any heavier
motor will just take away from the payload allowance which is already tight. 

If I shave about 8-10 grams, a larger battery can be used to increase the Fly Time...my goal.

Keep in mind that this is an endurance build, not a "Hi-performance" craft.

Now, to fix that arm and get the Unsanctioned-1 ready to fly again.

Niiiccceeee

OOOOOOOOOhhhhh, an iFly build! I always love how you make the parts fit mate! You can definitely see the (home) builder in you, just the way you go about solving various issues speaks to the real world experience you have. On another note I really hope your son appreciates the work you have done on the home build!

Hi ph2t,
Thanks. Didn't know it showed. 

Yeah, I actually tried to make this one look a little cleaner, nicer.
Normally, if it flies well, I really could care less about how it looks. 
Hey, these things are Not Beauty Queens.

Yes, we have our son, now. He really does appreciate what we are doing for him and is very excited.
Maybe, his life will go smoother from now on. Ah, we pray.

2022-03-09

The Unsanctioned-1 one has been repaired and is ready to Fly.

The Process:

1) Remove the bottom brace and the front arm pair.
2) During the re-alignment, the arm broke completely.
3) Position the two arm pieces and use Bonidic {UV curable plastic} to hold the two pieces together.
4) Cut a brace plate from 0.5mm Carbon Fiber sheet.
5) Glue the brace plate to the arm pair with J-B Weld clear 2-part epoxy.
6) Fill the oblong holes with original gray J-B Weld 2-part epoxy.
7) Drill mount holes through new plate.
8) Grind plate to better match the contour of the arm pair.
9) Re-assemble the arm pair and bottom brace plate.



{2022-03-20 Edit: Pictures added} The Unsanctioned-1 is back together with the repaired arms.







~~

I still can't believe you actually went ahead and tried to repair that man that's some determination!!

Lookin good!!!

(11-Mar-2022, 05:20 PM)the.ronin Wrote: I still can't believe you actually went ahead and tried to repair that man that's some determination!!  

Lookin good!!!

Hi Ronin,

Yeah, the repair actually went very smooth. This is like a standard type of repair for me 
{not just drones, but other things as well}. I tried "flexing" the arm pair and it did NOT
flex so I think it is a solid repair. The Unsanctioned-1 is back together...now we are waiting
on the rain to stop so we can get him in the air.

I will get some pictures when he is suited up...and...let you how he flies.

A little late to the party.

The repair looks good! ( I love fixing stuff )

Also waiting for better weather.

Scott

2022-03-16

Well, I managed to get the Unsanctioned-1 out for a test flight. This is the first one since the repair of the
broken arm.  I didn't have a full battery, so I just used one that was on the bench. 

Yet, another windy day at the park; maybe windier than the other day. Overall, the flight was pretty good.
It seemed like I was fighting the wind quite a bit, so I can't really tell yet how it will handle on a calm day.
I also didn't fly that long; only about 3 1/2 minutes. I just wanted to see how it would fly and hold together.
In my opinion, the flight was pretty good given the conditions, the landing rough {as is my style, ha, ha} 
but most importantly, the arm repair held up and did not break. It is still extremely solid. So, I am ok with 
the repair. 

I still need to make some adjustments to the battery calibration and want to get some more time on this
one before making any hardware changes.

Very clean build Harry! I like the style of that frame and am very impressed as always how you can get that drone to be so light. And, lifting a 5" with a 3s battery? Holy hell man thats impressive as well. And getting 9-10 min. flight time at that. Good job man! I will be following this thread for sure.

(20-Mar-2022, 05:11 AM)wllmlutz Wrote: Very clean build Harry! I like the style of that frame and am very impressed as always how you can get that drone to be so light. And, lifting a 5" with a 3s battery? Holy hell man thats impressive as well. And getting 9-10 min. flight time at that. Good job man! I will be following this thread for sure.

Hi Bill,  Thank You.

I am just getting started with this one which, by nature of the beast, is an experimental build.
Given the that the frame is a prototype, I will be trying different things. Although I like the 
motors, I might try something different. 

I will be posting more pictures and try to get a video. I have abandoned YouTube...so....
maybe try AirVuz. Something???

Still building the house for our son, so FPV time is a bit limited.

Good to hear from you my Friend.