Excalibur Firewall Enforcement

thingiverse

This is a Firewall enforcement for the Durafly Excalibur sold by HobbyKing. It's an excellent plane for the money, but unfortunately they came with a motor mount that's too weak to handle the forces when the motor starts and stops. After just a few flights I had mine broken out and it crashed. I purchased a new cowling, cut a plate from 2mm woven carbon fibre, and placed it on the outside of the motor. Since I kept the same dimensions, the propeller is now 1 or 2mm farther forward. Someone at my club loved the Excalibur so much that he bought one too. Therefore, I decided to print one for him with the help of a friend who's skilled with SolidWorks. We didn't have the Excalibur handy, but we knew the dimensions should fit. I believe it's easy to create a design that won't break under any force, but harder to make something just strong enough. That's what I did with this design. Alongside the original motor mount, this should prevent the experience I and some others had. It's also very easy to install and doesn't change the dimensions at all. I would replace the screws with nice titanium bolts that have cylinder heads, just like I did. Apply some glue between the dish and the original motor mount. I used Foam-Tac, but other glue that stays a bit flexible will do fine. After noticing a few little things when mounting it for real, I made a V2. It's 3mm thick instead of 2mm (which should still fit nicely). It has some extra room for the extender shaft; it should be able to go in 2mm. The bolts now have a 3.1mm hole and the sunked in part is now 5.2mm. The ventilation holes are straight to make it stronger. Print Settings Printer: Mendelflex Rafts: No Supports: No Resolution: 0.1 Infill: 100 Notes: I used ABS-PC (ABS with Polycarbonate), but ABS will do fine too. PLA probably works, but it's somewhat brittle and also weakens a lot when warmed. I would recommend using ABS at least.