Disaster Strikes: DIY REAPER Drone Gone Wrong

Table of Contents

1. Introduction
2. Designing the Wood Frame
3. Assembling the Wood Structures
4. Covering the Wings in Foam Board
5. Adding Fiber Reinforced Tape to the Wing
6. Building the Fuselage with Foam Board
7. Attaching the Parts with Hot Glue
8. Incorporating 3D Printed Parts
9. Using Lightweight PLA for Specific Components
10. Painting and Finishing Touches
11. Adding Electronics for Autonomous Control
12. Testing and Flying the DIY Drone
13. Troubleshooting and Crash Recovery
14. Future Improvements and Recommendations
15. Conclusion

Building a DIY Drone with a Two Meter Wingspan

Drones have become increasingly popular in recent years, and when people think of drones, they usually envision quadcopters or smaller remote-controlled planes. However, today, we will dive into the world of a large DIY drone with a remarkable two-meter wingspan—the MQ-9 Reaper.

Introduction

The MQ-9 Reaper is a unique and completely DIY project that utilizes laser-cut wood, foam board, and some 3D-printed parts. This endeavor not only showcases the creator's creativity but also provides an opportunity to learn essential skills like designing for laser cutting and incorporating various materials. In this article, we will explore the step-by-step process of building this impressive drone and discuss its potential for autonomous flight.

Designing the Wood Frame

The first significant step in building the MQ-9 Reaper is designing the wood frame. Quarter-inch plywood is utilized for its lightweight properties, and the wood pieces are kept minimal to reduce overall weight. While balsa wood would be the ideal choice, the affordability and lightweight nature of the plywood make it an excellent alternative. The fuselage and wing structures consist of ribs and spars, creating a Puzzle-like assembly process that is both satisfying and efficient.

Assembling the Wood Structures

Assembling the wood structures is a crucial and exciting part of building the drone. The wooden pieces are carefully cut out and fitted together, creating a rigid and robust frame. Carbon fiber tubes are used to hold the wings together and attach them to the fuselage, providing both rigidity and easy removal.

Covering the Wings in Foam Board

To cover the wings, foam board is an excellent choice. Its lightweight nature makes it ideal for RC planes, and its laser-cutting capabilities ensure precise and efficient construction. The foam board is carefully cut and Shaped, and fiber-reinforced tape is added to the trailing edge and seams of the wing for added durability.

Adding Fiber Reinforced Tape to the Wing

While fiber-reinforced tape may not provide the most aesthetically pleasing look, it significantly enhances the wing's durability. This reinforcement is essential, as it ensures that the wings can withstand the stresses and strains of flight.

Building the Fuselage with Foam Board

Similar to the wings, the surface of the fuselage is constructed using foam board. However, instead of using large pieces, several smaller ones are employed to simplify assembly. The king of all tools, hot glue, is utilized to attach and secure the foam board pieces together.

Attaching the Parts with Hot Glue

Hot glue continues to be the adhesive of choice for various parts of the drone. With its quick-drying and strong bonding capabilities, hot glue ensures that the different components are securely attached to each other. Its versatility makes it an essential tool in the drone builder's arsenal.

Incorporating 3D Printed Parts

To enhance the drone's functionality, 3D printed parts are utilized for more complex features. Lightweight PLA plastic is chosen to reduce weight, allowing for a sleeker and more streamlined design. Apart from lightweight PLA, the ailerons are also constructed using this material, enabling the integration of hinges into the wings.

Using Lightweight PLA for Specific Components

Continuing with the lightweight PLA material, specific components such as the control surfaces on the v-tail and other complex features are crafted using this material. The combination of foam board and lightweight PLA allows for quick wing construction while maintaining proper airfoil Shape and structural integrity.

Painting and Finishing Touches

After completing the construction phase, the drone undergoes a paint job, adding a touch of personalization and visual appeal to the aircraft. The finishing touches not only make the drone aesthetically pleasing but also protect the materials from wear and tear during flight.

Adding Electronics for Autonomous Control

For autonomous flight capabilities, the drone requires electronic components to interpret and execute commands. The Matech 405 flight controller, RC receiver, telemetry radio, and GPS enable the drone to operate autonomously using RG Plane software. These components work together, allowing the drone to fly independently and respond to user commands.

Testing and Flying the DIY Drone

With the drone fully assembled and equipped with the necessary electronics, it is time to test and fly the MQ-9 Reaper. Initially, HAND launching the drone enables smooth takeoff, and once in the air, it exhibits excellent flight characteristics and stability. The drone's large wingspan and sleek design allow for impressive maneuvers and an overall enjoyable flying experience.

Troubleshooting and Crash Recovery

While no project is without its challenges, crashes can sometimes occur during the testing and flying phase. In the event of a crash, it is important to survey the wreckage and assess the extent of the damage. Often, cosmetic fixes and repairs using tape can quickly remedy any issues.

Future Improvements and Recommendations

Though the MQ-9 Reaper project may have encountered some setbacks, there is always room for improvement. For future iterations, utilizing more robust materials like foam may enhance the drone's durability. Additionally, considering weight distribution and fine-tuning aspects like control surface throw can improve flight performance.

Conclusion

Building a DIY drone like the MQ-9 Reaper provides an opportunity to explore various construction techniques and learn valuable skills in the process. From designing the wood frame to incorporating foam board and 3D printed parts, each step contributes to the creation of a unique and functional UAV. While challenges such as crashes may arise, they offer valuable lessons and opportunities for growth. By embracing the DIY spirit, drone enthusiasts can personalize their aircraft and Delve into the exciting world of autonomous flight.