Structural-Mechanical
Under construction
Boom
While weights vary by diameter and wall thickness, carbon fiber is generally 200-300% lighter than aluminum with potentially twice the strenght. On the other hand, we don’t need much material and aluminum is easier to work with. My approach is to use aluminum for the initial version and testing and CF for a final version.
Paul Martin reports that if you just want to bolt a tube on to get up and running anything, from 1.75” x 17 swg is fine (commonly used in old hang gliders).
TBD: Add link to Paul’s engineering doc.
Credit: Paul Martin
Credit: Reidar Bernsten
Credit: Brendan
Boom to boom hinge connection
Credit: Charles Allen
Backplate connection
TBD: explanation. We don’t know the shear strength.
Make or buy a mechanical fastener that provides both a non-crushable metal bolt sleeve as well as a top and bottom surface for the fastener: T nut, weld nut, grommet, TBD. Stainless steel is NOT epoxy friendly.
Mark and drill the backplate holes.
Abrade and degrease the backplate and fastener.
Bond with a high strength epoxy to both sides of the hole.
Clamp. Compressing with a nylon bolt may be easier than a tool.
Credit: Paul Martin
Motor mount
Credit: Paul Martin
Credit: Reidar Bernsten
Credit: Charles Allen
Credit: Charles Allen
Battery mounts
TBD
Kickstand
Credit: Paul Martin
Design by Charles Allen
Safety features
See Safety Checklist
Part suppliers
No attempt is made to provide a definitive list.
Wheels
Wheel pants, wheel fairings
Hang glider hardware
General suppliers
Hobby King <https://hobbyking.com/>: Just about everything.
Carbon fiber
Dragonplate: Includes technical specifications, CAD drawings, and connectors
https://www.clearwatercomposites.com/products/carbon-fiber-tubes/round/