So, I was planning on building a Giant Santas Sleigh for Christmas, but the print shop I was trying to use couldn't get me the laminated graphics in time. So I took the parts I had available and built a 72" Nutball for New Years instead. 
Specs:
72" Wingspan
1" Owens Corning XPS Foamboard from Home Depot - 2x 4'x8' Sheets
Hobbyking Donkey ST4010-820kv Motors x2
Hobbyking 60A Blue ESC x2
5000mah 20-30C 4s batteries x2
4000mah 40c 3s battery for lights and ballast
Master Airscrew 13x6 3 Blade counter rotating props
Corona DS-319MG Servos x2
1/8" Steel Tig welding Rod
5050 Red, Green, and White LED strips
A few cheap carbon fiber arrows
and some 1/4" plywood servo horns I cut on my CNC.
I used a cheapo projector to transfer my plan outlines to the foamboard:
Did most of the cutting with a slightly dull filet knife. Was going to use the hot wire cutter, but I broke the wire on my first attempt and was in a huge hurry.
Cut out servo horns, control rod supports, and the firewalls out of 1/8" plywood on my CNC which I then CA'd together to get 1/4" parts. I haven't cut much wood, and the setting were a little rough, but once again, I only had a day to build this.
Embedded carbon fiber arrow:
Duct tape is your friend.
You can see where the carbon arrows went. I'm going to add a couple more. The gaps on the bent section of the circle were filled with scrap bits of foam, then hot glued into place.
Motor pods installed:
*********************************************************************************
All ready for the maiden flight:
Battle Damage. I had 3 mortars blow all the way through the foamboard. Left nice melted holes in the plane, one on a hinge line lol.
Specs:
72" Wingspan
1" Owens Corning XPS Foamboard from Home Depot - 2x 4'x8' Sheets
Hobbyking Donkey ST4010-820kv Motors x2
Hobbyking 60A Blue ESC x2
5000mah 20-30C 4s batteries x2
4000mah 40c 3s battery for lights and ballast
Master Airscrew 13x6 3 Blade counter rotating props
Corona DS-319MG Servos x2
1/8" Steel Tig welding Rod
5050 Red, Green, and White LED strips
A few cheap carbon fiber arrows
and some 1/4" plywood servo horns I cut on my CNC.
I used a cheapo projector to transfer my plan outlines to the foamboard:
Did most of the cutting with a slightly dull filet knife. Was going to use the hot wire cutter, but I broke the wire on my first attempt and was in a huge hurry.
Cut out servo horns, control rod supports, and the firewalls out of 1/8" plywood on my CNC which I then CA'd together to get 1/4" parts. I haven't cut much wood, and the setting were a little rough, but once again, I only had a day to build this.
Embedded carbon fiber arrow:
Duct tape is your friend.
You can see where the carbon arrows went. I'm going to add a couple more. The gaps on the bent section of the circle were filled with scrap bits of foam, then hot glued into place.
Motor pods installed:
*********************************************************************************
All ready for the maiden flight:
Battle Damage. I had 3 mortars blow all the way through the foamboard. Left nice melted holes in the plane, one on a hinge line lol.
