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Parts Description
Chassis
Figure #1
Carbon Fiber Rods
Figure #2
Carbon Fiber Square
Figure #3
Speed Controller
Figure #4
Nuts
Figure #5
½ In. Screws
Figure #6
4 In. Screws
Figure #7
Strips
Figure #8
1
Motor Mount (Before)
Figure #9
Motor Mount (After)
Figure #10
White Wire
Figure #11
Black Wire
Figure #12
Red Wire
Figure #13
Motor
Figure #14
Black Tape
Figure #15
Propeller
Figure #16
2

Important Information Icons

Like any other project that involves the use of machinery, a quadrotor must be
constructed carefully. The physical integrity of the quadrotor and the user of the manual
can only be kept safe if the guidelines shown in this manual are followed closely. In fact,
safety is the main purpose for the creation of a manual like this. In order to effectively
inform the user about risks, recommendations, and precautions while building the
quadrotor, this manual makes use of different icons and/or visuals. This section is
dedicated to the explanation of those icons and/or visuals used throughout the text.
Safety Goggles required
As noted from the above icon, the user will be required to wear safety goggles before
completing the step where this icon is located. This requirement will appear every time
the user is exposed to a procedure that involves working with construction materials.
Moreover, the user’s eyesight should be protected every time sawing, drilling, or milling
machines are used.
Warning
Every time that this icon appears, the user must stop and read the important information
regarding the risks involved in following a step. The failure to read this warning
information might cause an accident. This icon is probably the most important one
regarding safety. This warning information is also intended to prevent mistakes when
building the quadrotor.
Note
This icon symbolizes important information about special indications in order to prevent
mistakes when building the quadrotor. Furthermore, this visual represents
recommendations to facilitate the construction process. Reading these notes will ensure a
successful final product.
3
Machines Used to Build the Quadrotor Parts
Sawing Machine
Figure M-1
A sawing machine is a tool for cutting
materials with a serrated blade. This
serrated blade consists of a toothed edge,
where the teeth are bent to a specific angle.
This machine is powered by electricity.
Warning: Keep hands and clothes
away from blade.
Safety Goggles must be used at all
times when operating this machine.
In case of trouble using the
machine, contact a technician in room 415
of the Clyde Building.
Milling Machine
Figure M-2
A milling machine is a tool used for the
shaping of different materials. It consists of
a rotating cutter or endmill and a movable
table, where the material to be worked on is
fixed.
Warning: Keep hands and clothes
away from rotating parts of the machine.
Safety Goggles must be used at all
times when operating this machine.
In case of trouble using the
machine, contact a technician in room 415
of the Clyde Building.
4
Polishing Machine
Figure M-3
A polishing machine is a tool used to create a
smooth and shiny surface by buffing
materials.
Warning: Keep hands and clothes
away from rotating parts of the machine.
Safety Goggles must be used at all
times when operating this machine.
In case of trouble using the
machine, contact a technician in room 415 of
the Clyde Building.
Soldering Machine
Figure M-4
A soldering machine is used to bond metal pieces together by melting solder between them.
Warning: Flammable objects must
be kept away from the soldering Machine.
Soldering machines can be found in
room 426 of the Clyde building.
Useful information for soldering can also be
found online at
www.miniaturemolds.com/soldinst.htm.
5
Drilling Machine
Figure M-5
A drilling machine is a machine used to make holes in different materials with a rotating cutting tip.
Warning: Keep hands and clothes
away from rotating parts of the machine.
Safety Goggles must be used at all
times when operating this machine.
In case of trouble using the
machine, contact a technician in room 415
of the Clyde Building.
6

Instruction Set for Building the Parts of a

Quadrotor
The most effective way of explaining the different steps involved in the quadrotor
construction process is to split the instructions into two stages. The first stage includes
preparation procedures, and the second stage includes the construction process, where all
the pieces of the quadrotor are finally put together. The main structure of the quadrotor
consists of a set of main pieces built separately. The first stage will guide the user through
the process of building those parts, so they can be put together in Stage 2.
It is important to note that this set of instructions will guide the user step by step through
the process of building a quadrotor. This manual provides notes and warnings to the user,
from researchers to help avoid making mistakes. This manual of instructions should help
reduce time consumed by troubleshooting, and it should make the overall process of
learning easier for the user.
NOTE: Please notice that all the machines used on the manual have a
label M followed by a number (i.e. M-1). The actual pictures follow the
same format, but instead of a letter M, the label is a letter A. The
measurement models also follow the same format, but instead, the label is
“Model.”
7
 Stage 1: Building the Parts of a Quadrotor
In this stage, the user will be guided step by step to convert the raw materials (See figures #1 - #16)
into the parts that make up the completed quadrotor. In this stage, the user will operate the different
machines introduced in the previous section.
These instructions are designed to make the task of building a quadrotor easier and more
user-friendly. Please notice that some of the steps have a symbol or icon indicating the
need of safety actions.
NOTE: Please read each step carefullyB EFO RE performing any action.
One missed step can ruin the entire project.
Building the main frame 1.1
The main frame is one of the most important parts of the quadrotor. The main frame is
composed of a metal frame with 4 carbon fiber rods, four 4-in. screws, and a carbon fiber
bottom floor. The main frame should be the strongest part of the quadrotor because it is
the part that will hold the aircraft together when the strong forces are applied.
1- Use a provided piece of aluminum bigger than 4 by 4 in. and at least ½ in. thick.
Check that both sides are smooth and have no scratches. The stronger the
aluminum compound is, the better the main frame will be. Aluminum #16 is the
recommended type.
2- Draw the dimensions on the aluminum using a FINE permanent marker (See
Model #1, Pg #8) using the measurements below:
Metal Frame
Model #1
NOTE: It is always a good idea to draw the lines a few mm larger, to have
8
a small margin of error. It will be a lot easier to polish 1 to 3 mm of excess
off than to start a brand new metal frame.
3- After drawing the accurate measurements, proceed to cut the outside of the
aluminum piece using the sawing machine (See figure M-1, Pg #4).
4- The product should be a perfect aluminum square (4 x 4 in.). Now using the
milling machine, (See figure M-2, Pg #4) mill down the center of the piece.
WARNING:
While milling down the center, do not take off layers too thick all at once.
Instead, take off 3 to 4 mm (max) layers at a time. This will avoid the
ruining of the metal frame and also the overheating of the machinery caused
by the overload.
5- Finish by polishing or grinding the metal frame using the polishing machine (See
figure M-3, Pg #5).
Drilling the holes in the metal frame 1.2
Main Frame Holes
Model #2
1- At the center of each corner, using a 5 3/8 tip, drill through the metal frame (See
Model #2, Pg #9).
2- Measure 2 in. from each corner. Then drill a whole all the way through using a 2
3/8 tip (See Model #2, Pg #9).
9

WARNING:
Make sure to drill all the way through the aluminum, or the frame will be weak for future
testing. Also, secure the frame with clamps before starting drilling so the force of the
machine does not bend the metal frame.
3- Drill a hole to the left of the center side holes using a 3 3/8 tip at a negative 45-
degree angle from the ground. Only drill halfway through the metal frame (these
holes are for the legs). (See Model #3, Pg #10).
Main Frame—Negative 45-Degree Holes
Model #3
10
Building the legs for the main frame. 1.3
Attach the legs of the quadrotor to the main frame for later testing. At the end of the
project, the user will be required to test the legs because landing tests will be very hard on
the quadrotor hardware.
1- Locate 4 to 6 feet of a carbon fiber rod (See figure #2, Pg #1). The dimension
should be 4 mm in diameter.
2- Using the sawing machine, (See figure M-1, Pg #4) cut 4 carbon fiber rods in 7
1/2 in. pieces.
Main Frame Legs
Model #4
Building the motor mount connectors.1.4
1- Locate 4 to 6 feet of carbon fiber rods (See figure #2, Pg #1). The dimension
should be 8 mm in diameter.
2- Using the sawing machine, (See figure M-1, Pg #4) cut 4 carbon fiber rods in 7
1/2 in. pieces.
Motor Mount Connector
Mode #5
Building the Main Frame 4 main columns. 1.5
1- Locate 4 to 6 feet of carbon fiber rods (See figure #2, Pg #1). The dimension
should be 4 mm in diameter.
2- Using the sawing machine. (See figure M-1, Pg #4) cut 4 carbon fiber rods in 2
1/2 in. pieces.
Main Frame 4 Columns
Model #6
11
Building the motor mounts 1.6
The motor mounts are the pieces that will keep the motor in place. They will also connect
the motor to the carbon fiber rod, which will also be connected to the main frame. The
motor mounts will be suffering a great amount of force. Therefore, Aluminum #16 is the
recommended metal. Plastic is another reliable option.
1- Locate the aluminum block. Using the sawing machine, (See figure M-1, Pg. #1)
cut a metal block for the motor mounts with the dimensions on Model #7.
Main Frame Block
 Model #7
NOTE: Make sure that the piece of metal is a solid block. The aluminum 3-
D rectangle cannot have any holes or dents in order to satisfy the desired
goal.
2- After obtaining the aluminum block, proceed to mill the center of the metallic
shape with a milling machine (See figure M-2, Pg #4). Use the dimensions shown
in Model #8:
Motor Mount after milling
Model #8
WARNING:
While milling down the center, do not take off layers too thick all at once.
Take off 3 to 4 mm (max) layers at a time. This will avoid ruining of the
metal frame and overheating of the machinery caused by the overload.
3- Using the sawing machine, (See figure M-1, Pg #4) cut 4 exact rectangles using
12
the dimensions in the following diagram (Model #9):
Motor Mount Template
Model #9
NOTE: This is probably the hardest and the most important part of making
the quadrotor. A minor difference on the measurements or on the any of the
shapes could cause an unbalanced aircraft.
4- After polishing all four motor mounts, the end result should be four exact
rectangular shapes that look like Model #10:
Final Motor Mount Measurement
Model #10
WARNING:
Make sure that to secure and hold the middle of the motor mount with
clamps to prevent the piece from bending with the pressure exerted from the
drilling machine.
13

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