NEW DIY Foil Drive Assist KILLER from Austria

[heiguga]

I created two prototypes of DIY Foil Drive Assists.
First prototype:

• everything sealed, very compact/light
• battery (12s2p) can not be changed
• XTs90 “loopback” for anti-spark on/off

Second prototype:

• replaceable battery
• battery option A) 12s1p sealed
• battery option B) 4 pieces 3s2p connected in a waterproof box
  (each battery 3s2p has 99Wh perfect for traveling/flying)
• No anti spark solution yet for the MT60 connector. Any ideas?
  (3 pole MT60 is used because BMS charging and uncharging need a separated connection)

Remote for both is a Flipsky VX3.
Antenna integrated in the build.
Connection test have been very sucessful.

Videos coming soon at

Robert Robbie

Here some pics, Regards Robert
PS: I am also working on a pure efoil with 14s6p. I will create an independent thread for this.

First prototype:

Second prototype:
with battery option A (12s1p sealed)

with battery option B (4 pieces 3s2p connected in a waterproof box, separate for flying…)

not finished yet:

Remote tests:

[windego]

Looks bomber. What are the specs on the aluminum extrusion?

[S_Roger]

Nice work @heiguga! I think you may have some posting limits if this is your first post, but it should get upgraded quickly automatically, especially if you engage a bit more on this thread (or others).
There’s been quite a few people thinking about doing one of these FD Gen2 style DIY builds, but I don’t think many (any?) have shared a finished project. Hopefully you can share more details soon!

[heiguga]

@windego

Looks bomber. What are the specs on the aluminum extrusion?

It is just a aluminum “U”-Shape → put all electronics inside and seal it.
I sealed it with epoxy which I got a few years ago from a guy from this forum.
I used it for my electric paraglider (winch).
I think his name was Thomas.
If he reads this, thank you again. You may can tell us what epoxy I am using here :-).

[windego]

Some great ideas there!

[macfly1202]

Thanks for sharing ! Some nice idea ! is it a FLIPSKY VX3 or the new FLIPSKY VX3 PRO (with new RF) ?

[heiguga]

@macfly1202

FLIPSKY VX3

I have tested and installed the old FLIPSKY VX3. Had no connection issues at all in the pool.

[rttn]

The prototype seems a little unfinished to me. I think this detail, coordinated with his aesthetic, will make him perfect.

I hope you won’t be offended, it’s just a joke.

[heiguga]

Some final tests have been successfully accomplished yesterday!
Both prototypes work perfect
Water temperature was about 5°C.
First session on the lake will be this weekend!

[FoiledBySpoil]

Good luck with your testing. Working on a similar build and thanks for inspirational simplicity. I was definitly overthinking many things looking at this build

Did you consider potting the bms separately since they seem to fail more often than a good battery pack, to be able to replace it? Or is it soft potting epoxy you are using so it can be unwrapped?

[lishine]

What is the width, height and wall thickness of the aluminum tube? The 12s2p variant

[gazlinux]

The video of you paragliding your opensource DIY ewinch (your youtube channel you posted at the start of this thread) is very Wright Brothers inspiring. Love it. Good stuff!

[heiguga]

testes every setup possible.
“travel” battery works great too.
first test ride:

DIY Foil Drive Assist

“travel battery”

[heiguga]

I am currently using a daly bms with charging only.
Next time I would put it in the very front to be able to change it on demand.
Do you have any recommendations for a reliable bms (12s lion)?

[heiguga]

45mm hight, 100mm width
1,5mm alu

[heiguga]

It was my first time on a winch ever (after a lot of testing of course).
I think the feeling was close to the Wright Brothers feeling :-).
I still have not yet tested any other winch but have already 100 of starts on mine and could not think of anything better.

[heiguga]

STL for the front of the travel battery (bopla box)

travel_battery_front.stl

STL for a improved gong motor mount (more stable + cable)

motor_mount_v02.stl

[lishine]

And you have there additional support around the screws? Otherwise 1.5mm maybe too thin…

[FoiledBySpoil]

Many recommend LLT bms for 12s I have not used bms, another common option is having only balancing cables and jst-xh sticking out, for RC charger

[FoiledBySpoil]

Thank you for validating the design . I’ve started the same build now. Gave up the probematic gen1 box and took all the parts out.
I have a 5mm carbon plate 3k quality lying around. Considering as bottom plate instead of the alu, having M3 bolts sticking up to mount a 3d printed lid.