3DLabPrint Joker Hotliner Build Log

[dehager]

I decided to build a 3DLabPrint Joker and Spitfire over the winter months. It has been a fair amount research locating the required components so here is a list of what I will be using for the Joker build. The first print went well using the recommended settings from 3DLabPrint and Simplify3D on my Prusa i3 MK3S printer. Updates to follow as the build progresses.

In the next updates I will go over my review of the printing processes, post print processing, component selection and assembly.

Components
EMAX GT2215 GT2215/09 1180kv Motor
Turnigy Plush 30A ESC
Turnigy Nano-Tech 3S 65C-130C 1800mah Lipo battery
Turnigy Nano-Tech 200mm Battery Strap

Frsky GRX8 Vario receiver
(2) HTX900 Micro Servo, 9g
(4) Corona DS-239MG Slim Wing Servo, 22g
(2) 15cm servo extensions
(2) 45cm servo extensions

Aeronaut Cam 10"X6" (25.5x15 cm) blades
Aloft Hobbies Turbo Folding Prop Spinner, 36mm
Aloft Hobbies Turbo Folding Prop Spinner Collet, 4mm

MP Jet Plastic Clevises, M2
2mm all threaded rod
K&S Metals 0.039” (1mm) music wire (push rods)
Dubro #511 antenna tubing (0.074" ID 0.134" OD push rod housing)
Carbon fiber tubing - 6mm OD x 4mm ID x 360mm long, 6mm OD x 4mm ID x 640mm long
Miscellaneous hardware as called out in the 3DLabPrint manual

Fillamentum PLA Crystal Clear Iceland Blue, 1.75mm
Fillamentum PLA Crystal Clear Amethyst Purple, 1.75mm
colorFabb PLA/PHA Orange Translucent, 1.75.mm
Hatchbox PLA True Black, 1.75mm filament

BSI Insta-Cure+ Medium CA
BSI Insta-Set Accelerator



Print Times and Weights

Fuselage
colorFabb PLA/PHA Orange Translucent 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 17:00

Part Description - Factory / Actual
Fuselage part 1 - 32g / 35.15g
Fuselage part 2 - 42g / 44.90g
Fuselage part 3 - 23g / 25.21g
Fuselage part 4 - 25g / 26.26g
Fuselage part 5 - 17g / 17.31g
Fuselage part 6 - 19g / 20.08g
T Weight - 158g / 168.91g

V-Tail
colorFabb PLA/PHA Orange Translucent 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 04:13

Part Description - Factory / Actual
V-Tail part 1 Left - 11g / 11.86g
V-Tail part 1 Right - 11g / 11.86g
V-Tail part 2 Left - 8g / 7.86g
V-Tail part 2 Right - 8g / 7.83g
Total Weight -38g / 39.41g

Elevons
Fillamentum PLA Crystal Clear Amethyst Purple , 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 2:08

Part Description - Factory / Actual
Elevon Part 3 Left - 4g / 4.30g
Elevon Part 3 Right - 4g / 4.18g
Elevon Part 4 Left - 4g / 4.30g
Elevon Part 4 Right - 4g / 4.21g
Total Weight - 16g / 16.99g

Servo Holder
colorFabb PLA/PHA Orange Translucent 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 01:10

Part Description - Factory / Actual
Servo Holder - 8g / 8.37g
Central Wing Clip - 2g / 2.17g
Total Weight - 10g / 10.54g

Wing Center Section
Fillamentum PLA Crystal Clear Iceland Blue, 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 16:06

Part Description Factory / Actual
Wing Part 1 Right - 79g / 84.91g
Wing Part 1 Left - 79g / 84.86g
Total Weight - 10g / 10.54g

Wing Outer Sections
Fillamentum PLA Crystal Clear Iceland Blue, 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 18:38

Part Description - Factory / Actual
Wing Part 2 Right - 41g / 44.55g
Wing Part 2 Left - 41g / 44.59g
Wing Part 3 Right - 35g / 38.95g
Wing Part 3 Left - 35g / 38.90g
Total Weight - 152g / 166.99g

Wing Tips Sections
Fillamentum PLA Crystal Clear Iceland Blue, 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 11:55

Part Description - Factory / Actual
Wing Part 4 Right - 28g / 30.13g
Wing Part 4 Left - 28g / 30.14g
Wing Part 5 Right - 22g / 24.43g
Wing Part 5 Left - 22g / 24.44g
Total Weight - 100g / 109.14g

Servo Covers
Fillamentum PLA Crystal Clear Iceland Blue, 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 00:54

Part Description - Factory / Actual
Wing Part 1 Right - 5.5g / 7.11g
Wing Part 1 Left - 5.5g / 7.11g
Total Weight - 11g / 14.22g

Flaps
Fillamentum PLA Crystal Clear Amethyst Purple , 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 04:27

Part Description - Factory / Actual
Flap Part 1 Right - 5g / 5.87g
Flap Part 1 Left - 5g / 5.91g
Flap Part 2 Right - 7g / 7.62g
Flap Part 2 Left - 7g / 7.58g
Flap Part 3 Right - 7g / 7.47g
Flap Part 3 Left - 7g / 7.49g
Total Weight - 38g / 41.94g

Ailerons
Fillamentum PLA Crystal Clear Amethyst Purple , 1.75mm filament,
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 04:27

Part Description - Factory / Actual
Aileron Part 1 Right - 6g / 5.91g
Aileron Part 1 Left - 6g / 5.87g
Aileron Part 2 Right - 8g / 9.05g
Aileron Part 2 Left - 8g / 9.01g
Aileron Part 3 Right - 8g / 8.93g
Aileron Part 3 Left - 8g / 8.85g
Total Weight - 44g / 47.62g

Canopy
Hatchbox PLA True Black, 1.75mm filament.
Default 3DLabPrint processes in Simplify3D.
Print time (hrs:mins) 00:54

Part Description - Factory / Actual
Canopy Part 1 Front - 6g / 7.72g
Canopy Part 2 Back - 9g / 10.67g
Total Weight - 15g / 18.39g

 

[dehager]

All parts printed and assembly complete. Minimal cleaning was required using the 3DLabPrint profiles in simplify3D. A X-Acto knife and small needle files were all that was required to remove the brims and minimal supports. Parts fit is excellent and should provide strong glue joints and clean seams.

*****
A word of caution, one should not use wire cutters or scissors to remove the brims or other supports in thin wall printed parts!
The shock will cause the layers to split and crack the delicate structure. Scoring with a knife and gentle flexing is all the is required.
*****

Preparing for the hardware required a 1.6mm drill bit for the control horn clevis pin holes and a 3.3mm drill bit for preparing the holes to tap for the wing bolts using a 4x0.7mm tap.

All gluing was done with BSI Insta-Cure+ Medium CA and BSI Insta-Set Accelerator. No fogging or discoloration was encountered using these products. Next up will be installing the hinges, motor and radio installation.

 

[dehager]

Ready for the radio install...

Hinging process was to install one side with BSI Insta-Cure+ Medium CA and allow to set up. Then glue the mating side, align with some masking tape to hold in place and spray with BSI Insta-Set Accelerator .
.

 

[dehager]

Slow progress this week. Normally I would use Multiplex connectors for the wing servo harness but I want to be able to swap out servos and do repairs without unsoldering the connectors. Once I become comfortable with the design and durability I may change them. A little time consuming but making the servo extensions just the right length really makes for a nice installation. Color coded servo plugs are from Hansen Hobbies.

Elevon pushrods are complete. I used clevises on the control horn end and Z-bends on the servo side for simplicity and weight savings. Z-bends get a lot of bad press but its all in the details. Make sure the hole in the servo arm is sized to the pushrod wire and I like to add washers on each side of the servo arm to minimize any play in the linkage.

You can make washers of the required thickness out of milk jugs, soda bottles or any suitable plastic. Punch out a bunch of discs with a sharpened piece of brass tubing and then drill a hole sized to the pushrod wire size. No more slop...

.

 

[dehager]

Motor and ESC Install

Easy install and no surprises. M3x6mm, M3x8mm screws and M3 flat washers were used along with thread locker. Use the low strength (purple) thread locker here on the small M3 fasteners to prevent loosening due to vibration and the motor heat softening the PLA firewall. I will be printing a small spacer to fill in the gap between the firewall and spinner to give it a finished appearance.

Maiden flight will be with an Aloft Hobbies 36mm Spinner and an Aero-naut CAM 10x6 prop .


*** Important Note***

As with all motor installations, be mindful of the length of screws used to fasten the motor!
The fuselage has down and right thrust built into it but the firewall is not parallel, it is tapered. It will require different length screws or washers to adjust the length of the screw as it threads into the motor. Failure to do this may cause damage to the windings of the motor when you tighten the screws.

.

 

[qwijibo]

Wow, that came out beautiful, and I really enjoyed your detailed build log. Very nice!

I built one a while ago and have only flown it a handful of times, but really enjoy it. Good luck with your maiden!

 

[dehager]

Finally finished the FrSky radio install and setup. CG starting point will be 68mm and will require no additional weight. The final ready to fly weight with a 3S 1800mAh Lipo is 1292.00g. Jokerwings.com listed build weight is 1175g, so I feel good knowing that I could make small adjustment to the extruder multiplier in the stock gcode files and loose the weight next print.

Thanks qwijibo, I am patiently waiting for some good weather, maiden flight update to follow.

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