Bolt PWC · 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.

Interactive 3D viewerDownload current R5 files ↓Free · name and email required

The redesigned mount groups go from 12 to 4 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 remove 49.2 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.

R5 gear deck hardware: four M4×30 bolts, eight 18 mm OD M4 steel washers and four M4 locknuts; add four M3×25 bolts, eight 7 mm OD M3 washers and four M3 locknuts. The original fork fasteners remain separate. Deck/doubler thickness is 6+6 mm; the new printed base is 6 mm.

Assembly order

1. Print the four gear nodes in their supplied orientations. Each side now uses one front node at X340 and one rear node at X410. Keep the PWC-specific carbon leg lengths and lower nodes.
2. Print the drilling template at 100% and verify its 50 mm scale bar. Align the four existing M4 hole centers at X340/410,Y±25. Add four Ø3.3 mm anti-rotation holes at X356/394,Y±25 through the 6 mm deck and 6 mm plywood doubler. The 110×80 mm doubler stays centered at X375,Y0.
3. Use four M4×30 bolts with 18 mm OD load-spreading washers on both faces and locknuts. Add four M3×25 bolts, two 7 mm OD washers and one locknut each. Check the 7+6+6 mm printed/deck/doubler stack, real washer thickness and full locking engagement. Do not rely on one bolt per block.
4. Use both matching R5 F02 body sections and the R5 X385 collar; clearance channels remain open behind the gear gussets. Retain the original hardwood deck rails and bond instructions.

In the download: Full-size PWC drilling template

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