Bolt PC · simpler R5 mounts

Mount-only 3D views & step-by-step assembly →

Designed for supports-off printing in the supplied orientations. All current STLs pass a 0.20 mm geometric layer screen, with short two-ended bridges limited to 10 mm. Sliced toolpaths, actual printing, bond strength, landing loads and flight remain unverified.

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The redesigned mount groups go from 57 to 13 printed pieces. Continuous webs and sleeves replace small glued sections. Some other airframe and tail groups still have multiple pieces.

This is an assembly simplification, not a weight-saving revision. The changed structural groups add 84.5 cm³ of solid CAD volume; actual printed mass depends on material and slicing. Continuous material and bolted cage joints are intended to improve load paths, but strength still needs physical verification.

Added cabin hardware: four M3×20 through-bolts, eight M3 washers and four M3 locknuts. Use the original remaining metal fasteners. Check that each locknut engages completely without projecting into carbon, servo travel or wiring.

Assembly order

1. Print and dry-fit the motor mount, X175 frame, ESC hangers and all four gear nodes on the actual 12 mm carbon rails. Keep the original nose rail datum at X82.
2. Position front gear nodes at X340 and rear nodes at X410. Place the replacement crossframe leading face at X366 (284 mm behind X82); it ends at X386. Its four rail sleeves are 20 mm long; the separate gear nodes retain 48 mm rail engagement. The rear battery mounting holes remain X400,Y±42 on the rear gear nodes.
3. Fit the two cabin side trusses around the four longitudinal rails and the main/rear wing spars. Install the receiver crossframe between them. Add four M3×20 bolts, eight M3 washers and four locknuts through the holes at X578,Z±25, on both sides. Heads face outboard; check clearance to the rails. The 8 mm side webs mate to 4 mm crossframe flanges.
4. Fit the X662 tail frame and original servo tray; verify servo lead and horn travel before closing the body.
5. Use all six matching R5 center-roof sections and both R5 F02 body sections. Their clearance openings are required by the new continuous gussets and wing cuffs.

Tube fit and glue

1. Print the retained tube-fit and adhesive samples in the intended structural material. The load-bearing mounts use the PAHT-CF candidate profile; do not substitute foaming skin filament. Actual material and adhesive compatibility must be qualified.
2. Clean up only the brim and minor bore fuzz. A dry-fit should slide without cracking the printed socket. Do not enlarge holes indiscriminately or force carbon tubes.
3. Mark 40 mm insertion on each gear tube and align to its modeled root datum. The conical cavity behind the round socket exists for printing; it is not an insertion stop. Use the tube centerlines and original gear jig to set angles.
4. Dry-assemble the complete rail/gear/cabin group, battery tray, servo tray and adjoining skins before bonding. Ensure the four gear nodes are square and the strut fork hardware remains accessible.
5. Bond with the qualified adhesive and hold the continuous carbon members in a straight jig during cure. Keep bolt seats, access pockets and moving joints clear.
6. Check rail bonds, bolted joints, landing loads and motor vibration using the existing aircraft test plan before considering powered flight. Fit success alone is not structural qualification.

Replacement map

In the download: Geometry screen record