Mast:
The mast was built the same way as the wings. The mold is slightly more complicated as it consists of more than two parts. Design is from @visor360.
Glued the pieces and aligned them to be straight/90° respectively
Reinforced it with wood and glassed it over on the outside
Built an insert from forged carbon to hold the FR motor. The insert was built with a 2 part mold, filled with epoxy and cfk flakes pressed together. Pin holes to fix the motor were kept with two 5.5mm alu rods.
Finished insert
3 cfk tubes 10x8mm serve as cable channels. I put a 4th in front that could be drilled open later for passive water-cooling if necessary. The tubes just fit between the two halves. 60kg/m3 foam core sanded to fit the rest of the core.
Glued in 3mm cfk rods for better bonding
Inserts from stainless steel 1.4301. It was a pain to cut threads into this material, especially M6. I broke 2 tappers and had to drill the core a bit bigger and order some special tappers for stainless steel. Hole pattern is for RL and Flite
Put some caps to the end of the threads to get space for the screws and covered it with epoxy and cfk flakes.
Added some grease to the screws as a “release agent”
Printed a tool for alignment of the motor insert when putting the halves togetter
There are many layers of 300g/m2 biax bent around the edge at the top of the mast (@ the inside, not visible here)
3d printed tool to drill the fixing pin hole into the shell
Made the pins from titan to prevent corrosion and because I had never worked with it an wanted to try it. Quite easy to lathe, drill and even cut threads. Sanding/grinding it is really hard!
The 5.5mm pins are held in place with an M3 grub screw
Drill jig for the mast mounting holes (90x165) with bearings as drill guides. Arrows should point to the seam
HA wing from post above
RL and Flight hole pattern
RL and Flight hole pattern
Flight copy with Flyer800 wing and diys rear wing (needs an adapter to make it fit better)