Complete Build Guide

Summary¶

After following this guide, the builder has a flyable, calibrated libdrone Pro with Blackbox enabled, maiden flight logged, and the build documented. This skeleton is the direct replacement for the V2.4.6 WBS — it is the complete builder traversal from Day 0 to maiden, navigating through the atoms in the correct sequence with the connecting rationale.

Concept¶

Before you begin¶

The build takes approximately 25–30 hours of active work over 10–14 days — primarily waiting for prints and AliExpress delivery, not continuous effort. The most important thing to do first is read this entire guide before touching any component. Surprises on Day 12 are caused by information not absorbed on Day 0.

→ prep-and-parametrics explains why documentation assembly and FreeCAD variable entry come before any physical work. The parametric model is the single source of truth: one wrong variable propagates silently into every printed part. Read → variable-table-values and keep it open throughout.

Phase 0 — Procurement¶

Order on Day 1 without exception. AliExpress takes 10–15 days; that window is the printing window. → procurement contains the full BOM with MoSCoW priority ratings, supplier links, and a day-by-day order sequence. The most critical item to order first: O-rings, motors, capacitors, MR30 connectors. Czech hobby suppliers (HobbyDrone.cz, RCStudio.cz) should be ordered the same day.

Phase 1 — Coupons and structural validation¶

Before printing a single production part, validate the critical fits. → coupon-validation explains the coupon system: small test prints that verify geometry before committing to a 4-hour structural print. Coupon 8 (T-lock fit) gates the entire PCCF production run. Coupon 8b (rod interference fit) gates the pinch bolt adjustment. Do not skip the coupons — they exist because the geometry is tight and printer calibration varies.

Phase 2 — Production print run¶

→ print-production covers the full printing sequence: PCCF layers first (highest failure risk, requires hardened nozzle), then PETG arm shafts (vertical orientation, 3.5 hours each), then bumpers and accessories. Total: approximately 38 print hours over 5 days. → print-profiles contains the PrusaSlicer settings that matter. → stl-export-and-slicer-setup covers the FreeCAD export workflow before slicing begins.

The post-processing step — heat-gun treatment and epoxy wipe-coat on all structural PCCF and PETG parts — runs after all parts are printed and before assembly begins. Do not skip: it seals surface porosity and significantly improves delamination resistance.

Phase 3 — Airframe integration¶

→ airframe-integration is the Phase 4 assembly sequence. The order is fixed and matters: tabs into T-slots, then CF rods through all five layers simultaneously (they self-align), then Platform on posts, then motor mounts, then acoustic ring verification.

Understanding why each step happens in this order requires → sandwich-structure (the composite geometry), → cf-rod-architecture (why simultaneous threading is the alignment mechanism), and → floating-motor-mounts (the O-ring isolation system that the entire vibration strategy depends on).

Three EMC geometry features must be verified in FreeCAD before printing the Platform — → power-signal-separation explains what they are and why missing geometry cannot be retrofitted after assembly.

Phase 4 — Electronics installation¶

→ electronics-installation is the Phase 5 wiring sequence. Read it fully before soldering anything, because every wire must be routed to its final position before the FC/ESC stack is bolted down.

The EMC rules govern every routing decision. → star-grounding (one ground point, no loops), → twisted-pairs (motor phase wires, battery leads, I2C pairs), → capacitor-placement-emc (1000µF directly on ESC pads, no pigtail wire), → power-signal-separation (LEFT channel for signal, RIGHT for power).

Conformal coating is mandatory before first power-on — → conformal-coating explains the application sequence and why it must happen after all soldering is complete.

For the payload connectors: → gx12-connector-standard covers the D-D bore that prevents rotation, the double-nut retention, and why all 12 wires must be soldered to the FC before the Platform top layer is placed.

Phase 5 — Software commissioning¶

→ software-commissioning is the Phase 6 configuration sequence. The order of layers is fixed: EdgeTX transmitter model first, then Betaflight, then AM32 ESC, then HDZero VTX and goggles.

The Betaflight configuration is applied via CLI diff, not manual GUI entry — → betaflight-setup contains the exact diff and the UART assignment table. → betaflight-profiles covers the two PID profiles (standard and low-speed A2 compliance). → betaflight-gps-rescue covers the GPS Rescue configuration — particularly the return altitude, which must be set for each new deployment site. → edgetx-model covers the TX16S model setup and switch assignments.

The low-speed mode calibration is an outdoor step that cannot be done on the bench: → betaflight-profiles explains the calibration procedure. Target: GPS speed ≤ 4.8 m/s at full throttle.

Commit a complete configuration backup to the repository before the maiden.

Phase 6 — Acceptance validation and maiden flight¶

→ acceptance-validation is the gate before the maiden. Hard gates: mass budget within EASA A2 limit, GPS fix ≥ 8 satellites, motor directions correct. If any hard gate fails, do not proceed.

→ maiden-flight treats the first flight as a measurement event, not a celebration. Phase 1 is hover-only at 1m for 30 seconds. After landing: feel the motors, check the T-locks, download Blackbox. Phase 2 expands to slow circuits and a GPS Rescue test only after Phase 1 inspection confirms the build is within spec.

→ blackbox-analysis is the final step: open the Blackbox trace in the Explorer, verify the gyro noise floor is below −40 dB, verify the RPM filter is removing motor harmonics, verify the time trace shows 1–2 oscillation cycles settling after sharp inputs. The maiden Blackbox is the reference baseline for every future diagnostic.

Reference¶

Build phase summary¶

Procedure¶

How to use this guide¶

This is not a step-by-step instruction set — each linked atom contains the detailed steps. This guide provides the sequence and the rationale for that sequence. Before starting each phase: read the linked atom completely. Then execute. Do not read and execute simultaneously for the first time.

Rationale¶

The WBS (V2.4.6) was a single document containing all build phases. Every specification, torque value, and wiring rule lived in that document. When a specification changed, the WBS had to change. This skeleton delegates all specifications to atoms — this document provides only the sequence and context. A changed O-ring specification propagates to the floating-motor-mounts atom; this skeleton does not need to change.

Connections¶

requires: [] related: - sk-engineering-101 - sk-workshop-handout - sk-operations-manual leads_to: - sk-operations-manual