Hi MaxMaker & Hiorth,
Many Thanks for the feedback. The front wing is quite a complex 3D curve plus the cross section changes both in size and shape. Actually it has become even more complicated since I’ve introduced more fluid-dynamic details as the design is finalised.
I think it would be possible that someone with fabrication skills could roll an extrusion and/or fabricate the front wing from sheet - however my DIY skills are no where near that capable capable. However with the miracle of Fusion 360, 3D printers and USB milling machines anything seems possible now.
The proposed build is as follows…
There needs to be quite a bit of structural integrity in the board since it will need to support around 135Kgs between the arms and the mast. For this reason a skeleton made up of cnc cut 4mm ply is to be created first. Standard foam blanking will be glued into this. The whole board is then wrapped in glass fibre and strengthened in critical areas with carbon fibre and kevlar.
For the front & rear wings, arms & mast
The core of the front foil will be 3D printed in segments (My printer volume is only 200x200x180) which are then assembled in a jig to ensure alignment. The jig will be simple to build out of tubing and 3D parts. Sitting out dimensions will be pulled out of Fusion.
The trick is being able to create the core light enough. The flying RC boys are leading the way on creating light-weight 3D prints… I’m taking a lot of inspiration from those guy’s - https://3dlabprint.com/ - Quite incredible what can be done with 3D printing that has a practical use.
The assemble 3D cores will be wrapped in Carbon fibre and Kevlar.
Drive and motor.
I’ll be using a new 6KW Alien Power inrunner motor. These should be available Jan/ Feb of the new year. Details are sketchy at the moment but I do believe they are based around an 80mm dia body. This single motor will drive contra-rotating props through a gearbox I’ll be designing and building myself. As soon as I have this design I’ll share the details.
Couple of things I have still yet to design/ confirm that maybe you can help me with…
Speed Controller. Other than putting a skateboard unit in a plastic bag… has anyone designed anything else that is a little more refined?
Batteries. I was planning on building my own flush-fitting power pack that is a simple drop-in and lock utilising the carry handle to provide the locking mechanism. Has anyone any experience in sourcing LI-Poly AA-sized cells they can help me source?
Battery & Speed Controller Cooling. I was thinking of using aluminium plating and water cooling them. It would make sense to use the surrounding water to do that. However the only place you can place the intakes are down towards the wings. Which means that there is a considerable head that needs to be overcome by the pump. Has anyone experience in cooling these components and if so - what appears to be the best to use?
Many Thanks for your help