Home-Made Hexacopter for <$200

[Max]

After reading posts from itshell and seeing rod's hexacopter fly, I decided I wanted to build my own Hexacopter.

I wanted payload capabilities, and I figure 6 rotors is better than a tricopter or quad-copter.

My payload will be a hig-res camera for aerial photography, a camcorder and/or FPV gear.

So I first started off by buying a KK Multicontroller hexa version (not the HK quad version)

that was $25

Then 6 motors
6 ESC's and
1 set of props in both standard and reverse pitch (these come as a "set" of 6, 3 regular and 3 reverse pitch)

I also got 3pieces of 5/8 poplar and a piece if 1/8" doorskin I had kicking around.


The plan is to have it as bolt-down arms, since the hex can take up a lot of room if transported in the fully assembled position. So the arms will have to be able to pivot to make it smaller for transport.

Here are the bulk of the main components:

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134128&dateline=1326478362


The first step is to decide on the center-to center distance between motors. I heard 24-32" was good using the KK Multicopter controller board, so I aimed for 26" end to end.

The center section will be 8" diameter. Based on that I calculated 2 mounting bolts per arm, ,and wanted 2" between centers with 1" inset from the center.

I used a square to measure all the arms at the same time so that the bolt patterns were the same:

Here I lay out the poplar arms and scrive
http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134129&dateline=1326478362

One the arms were done, I wanted to cut out the center section of the hex.

This will be 2 pieces of doorsking that will sandwich the booms.

Using a compass, I measured 4" and used that to scribe the diameter.

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134130&dateline=1326478362

Then the same compass is used to generate a PERFECT hex pattern by starting on the circumference at any point and scribing intersecting lines on the circumference. The protractor is moved the the next intersection and the process is repeated all the way around.

The when the lines from the intersections are joined together through the center, the exact location of the tricopter booms are shown.

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134131&dateline=1326478362

This is repeated a second time so that you hace 2 pieces. Because these are mated top and bottom, it is easiest to cut them as one, so I bolted the 2 together before I started cutting

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134132&dateline=1326478362

Next step: Cutting :)

[Nev]

Looks cool Max ,keep the thread posts coming :)

[wparsons]

What motors/escs are you using? I've been looking into building one, but am having a hard time finding motors/escs that seem reliable but also fit a budget build. The frame looks very simple, but effective and solid.

[Fuzzydog]

Looks cool Max ,keep the thread posts coming :)

X2, I am very interested in watching this build. :D

[Mark L @ FL]

Max - Nice build thread, hope to see more.

wparsons - We carry motors, ESCs, controllers and other multirotor parts in Canada if you are in need of a local source - www.------------- Some items in stock now and more will be added in the coming months.

[buffythesaint]

Looking good Max. Keep it as light as psossible and you should have a nice hexa. If you want it to be super smooth, try to reflash your escs with a better program that rsponds better to throttle changes. Here is the link to the DIY project. I'm no expert but I was able to reflash some RCTimer 30a escs. What a difference in throttle response after reflash. This is for escs with the Atmega8 chip only, not the Silabs chip.
http://www.rcgroups.com/forums/showthread.php?t=1513678

[belcom]

Hey Max, interesting project you started. I just came across this frame for a hexacopter for only $40. Maybe it's something you would be interested in. I am not sure about the size though. Check it out anyway.

http://www.himodel.com/helicopters/Fiberglass_&_Aluminum_6-axial_DIY_Frame.html

They actually have a lot of of interesting things on that site including everything you need to build a DIY hexacopter etc. Just have to dig through it.

[Mark L @ FL]

Hey Max, interesting project you started. I just came across this frame for a hexacopter for only $40. Maybe it's something you would be interested in. I am not sure about the size though. Check it out anyway.

http://www.himodel.com/helicopters/Fiberglass_&_Aluminum_6-axial_DIY_Frame.html

They actually have a lot of of interesting things on that site including everything you need to build a DIY hexacopter etc. Just have to dig through it.

More selection here but its a bit buyer beware. I've had missing and wrong parts, poorly packaged, etc. Nice selection and prices but can be a gamble. A lot of these Chinese wholesale places carry a lot of the same items.

http://www.goodluckbuy.com/hobbies-and-toys/multicopter.html

[Max]

What motors/escs are you using? I've been looking into building one, but am having a hard time finding motors/escs that seem reliable but also fit a budget build. The frame looks very simple, but effective and solid.

I will hold of on the specs of the motors because I think I bought the wrong ones. From my initial tests I think my KV might be too high. When I am done the build and make the test flight with my flight data recorder, then I will know for sure. My gut tells me I will have to swap out all the motors to a lower KV because the motors I have at present will have too much of a current draw at hover... I hope I am wrong about this....:(

[Max]

Hey Max, interesting project you started. I just came across this frame for a hexacopter for only $40. Maybe it's something you would be interested in. I am not sure about the size though. Check it out anyway.

http://www.himodel.com/helicopters/Fiberglass_&_Aluminum_6-axial_DIY_Frame.html

They actually have a lot of of interesting things on that site including everything you need to build a DIY hexacopter etc. Just have to dig through it.

That is a nice frame. Definitely worth it for 40 bucks! it comes out at 24" end to end. Mine is 28" end to end. Same prop diamter specs. So it is very compatible. I might pick one up for my next project or to replace this one if this frame turns out to be an "epic-FAIL":rolleyes::rolleyes:

The only thing good about my wood one is if I have a crash, a new piece of poplar is only $1.50. Crashing an ally frame means you have to buy new ally square tubes.

[Max]

Looking good Max. Keep it as light as psossible and you should have a nice hexa. If you want it to be super smooth, try to reflash your escs with a better program that rsponds better to throttle changes. Here is the link to the DIY project. I'm no expert but I was able to reflash some RCTimer 30a escs. What a difference in throttle response after reflash. This is for escs with the Atmega8 chip only, not the Silabs chip.
http://www.rcgroups.com/forums/showthread.php?t=1513678


I read you thread on reflashing the ESC's in the FPV section, Brian. Looks very interesting but the complexity is scaring me for now. I think I will take this one-step at a time and see how it flies with the existing ESC's. Then maybe it will be time to reflash them :)

[Max]

After cutting, I marked out the position of the arm-mounting holes on each of the 6 side and drilled them out.

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134435&dateline=1326640505

It is important to maintain the orientation between the bottom piece and the top piece, so i made these orientation marks while they are still joined together. That way when I take it apart and separate the 2 pieces, they can still come together in the same orientation as they were drilled.
http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134436&dateline=1326640505

Arms bolted on! its starting to look like a hexacopter now!! :) :)
http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134437&dateline=1326640505

Now the motor mounts are made from the same piece of doorskin. I used 1-1/2" square lines for my mounts

http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134438&dateline=1326640505

Motor mounts glued on:
http://www.rccanada.ca/rccforum/attachment.php?attachmentid=134439&dateline=1326640505

[cicopo]

Following along with great interest. I expect I'll be building one in the near future thanks to DIY's like this.

[dege13]

No updates from Max in a while :(

FYI, Max, too much of a current draw at hover could be due to too large of props for the motors. My motors are 1200kv and Mark at ------------- (out of Halifax) suggested I use 2 blade 8"x4.5" props. Prior I was using 3-blade 9"x5" props. If you share what motors you have got I am sure that there are people here that can help out.
Here is a good video to help learn about prop sizes and current draw.
Flite Test: Choose Your Prop
http://www.youtube.com/watch?v=u-c1OFGpBxM

Keep up the good work and we are all eager to see more. Thanks!

[Florin]

Any updates on this project Max? I'm researching, as I want to build one myself.