Hey everybody, I have most of my parts, except for the box and the battery. My board is kind of small (35L), so a FD gen2 style box would be more practical than a gen1 box. I would also be open to buying a backpack-box if anyone sells those.
Stuff I already have:
-Flipsky 6384
-Flipsky 150A, 4s-12s 60V max (ip68 waterproof Mini FSESC6.8 Plus based on VESC6)
-motor pod, propeller, VX3 remote, bluetooth module
For the battery, I was thinking of using a 11s3p, or maybe just buying an off-the-shelf FoilDrive Slim Performance battery.
If anyone has suggestions for people who sell boxes, please let me know! Thanks!
The hardcore truth is that buying an underboard box won’t be very cheap. To CNC a Gen2 enclosure is in the region of $800 unless you have your own CNC capability. Then the guys that have designed them tend to design according to specific vesc or esc that they use.
Maybe not the answer you were looking for, but you could alter your design idea and try something like this build. Still a Gen2 style, but divided up into two enclosures that are mounted into a U-channel on either side of the mast. No CNC work necessary. Could even have SendCutSend cut and bend the U-channel part if you draw it up in CAD (which should be super easy). Then you can get holes cut exactly where you need for a mast mount.
I’m building one right now… I’m using 3D printed plastic as the form, then I’m going to glass over the print and add an aluminum plate for heatsinking and rigidity.
The whole thing will get epoxied together. No screws, no access, the whole thing will be one waterproof unit.
One more note: I have used the 6384 with the Mini FSESC6.8 and I found the motor controller gets very hot. The 6384 has 26 poles and the motor controller ends up needing to run near maximum ERPM… that seems to make it hot. Good tuning and heatsinking will be needed.
In comparison running a F5085 14 pole motor is way cooler for the same delivered watts.
What 3d printing material do you use? Not an easy shape to laminate over. 3mm radius insted of sharp edges helps, even when you put the part in a vacuum bag. I made some over laminated parts from asa. Maybe you could glue parts from 3mm solid carbon boards to the side to support the compression load between mast and board. Or use carbon tubes instead of 3d print as spacing sleeves around the mast screws.
The material right now is PETG which if sanded will take epoxy and glass OK… but I might print the end version in Polycarbonate. The existing prints will be used for a structural test and a frame to construct the battery.
I like your idea of carbon spacing sleeves… right now I’m hopeful that the supports will be OK since they’re always in compression once the mast screws are tight.
I used carbon tubes as supports when I printed a PETG front foil and that worked OK… I should see if I have anything left over.
