Measurement Units: For this guide I will be using metric measurements because the materials I used are in metric dimensions. If you are using materials in U.S. dimensions, use the second measurement number. e.g. 100mm/3.75″
Cutting Carbon Fiber
Scout’s airframe is constructed entirely from carbon fiber. Cutting carbon fiber is messy. The carbon dust gets everywhere. The dust is also bad for your lungs. When cutting carbon fiber, wear a face mask and eye protection and work in a well ventilated area.
To cut carbon fiber I used a Dremel mounted to a router table and use a 1/8″ carbide cutting bit. Alternatively, you could also us a cutting wheel instead. You could cut the carbon fiber freehand but I found the router table gave more precise cuts.
Make Airframe Plates
Take the sheet of Carbon Fiber and cut five 100mm/3.75″ Squares.
Take the vibration foam and cut a piece to the size of the ArduPilot Mega.
Take the 10.5mmx750mm square tube and cut four 180mm /7″ tubes for the arms
Make Motor Mount Plates
In order to mount the motors to the square tube we need to make 4 mounts out of the carbon fiber sheet.
Cut four 45mm/1.75″ squares
Take one of the cross plate that came with the motors and place it’s center hole to the top center of the 45mm/1.75″ square.
Cut and shape the carbon fiber square in the shape of a Y. Use cross plate as a template for shaping motor mount
The end motor mount should be shaped as a Y