Cut and Drill

March 15, 20110 Comments

It was a successful time in the garage last night. Again, it might not seem like tons of progress, but for a guy who is very particular with his projects this work is right on schedule. I was able to cut out the upper and lower frames, square everything up, layout the frame plates/components/boom arms and finally drill my starting holes for when I begin to mount the booms to the frame. I took a lot of pictures, so enjoy!

I began with clamping the carbon fiber plate to the workbench and I cut almost every line free hand with a Dremel. I started using a blade that had teeth on it – like the kind you would use to cut wood – and that didn’t work out too well. When I started using the carbon-like disk it was much more like a hot knife through butter! It made all the difference in the world – less heat, faster cuts, and slower speeds.


And here is the bottom frame. All cut out and ready to fly!!! Well, almost.

Next was the top frame. And since this carbon fiber plate is strong only in one direction I mad sure to cross the lower plate’s linear strength with the upper plate’s linear strength.

Once I had both the upper and lower plates cut out I wanted to stack them and line them up as close as possible and then grind down each edge where it didn’t line up perfectly.



Here they are, all finished.

A glimpse of how it will look

Yes that is BBC’s Top Gear playing in the background.

Wtih some fake components

I then stacked the two plates together again and got it ready to drill the holes for mounting the booms. I measured 1cm in from each end point and drilled a hole.

Next I spend a lot of time drilling the holes on the booms. Since I do not have a drill press I had to measure 5cm from the end of each boom, mark it, then find the center of the width of each boom.

I then used a drill punch to make sure I was starting in the right spot when I drilled and so the drill bit didn’t move on me when it started to spin. I did this on each side of each boom because I didn’t want to simply drill straight through the boom to the other side. Had I not been level with my drilling then the hole on the other side of the boom would not have been centered.

And that is all I had time for last night. I ordered some screws for securing the booms to the frames. And I still can’t wait until all the electronics start showing up on my front door. I only wish I had some tracking numbers for them. It’s too much agony just waiting without knowing!

Thanks for reading. And as always your questions and comments are much appreciated.

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About the Author ()

Fun-loving, off the wall, and energetic, this crazy red head sometimes enjoys building more than flying!

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