Project Quiver PT3 Structural Assembly Guide

BOM for the Assembly

Table 1. Structure parts

Part ID	Part Name	CAD ID	Material	Sourcing	Quantity
1	Upper plate	1101	Aluminum	Laser Cut	1
2	Middle plate	1102	Aluminum	Laser Cut	1
3	Lower plate	1103	Aluminum	Laser Cut	1
4	Cockpit Support Beam CW Long	1211	Aluminum	Laser Cut	1
5	Cockpit Support Beam CCW Back	1212	Aluminum	Laser Cut	1
6	Cockpit Support Beam CCW Front	1213	Aluminum	Laser Cut	1
7	Battery Wall Left	1221	Aluminum	Laser Cut	1
8	Battery Wall Right	1222	Aluminum	Laser Cut	1
9	Foldable Motor Arm Connectors	14X1	Aluminum	Off-the-Shelf	4
10	Motor Arm Tubes	14X2	Carbon-Fiber	Cut-to-Length	4
11	Landing Gear Vertical Tubes	1310	Carbon-Fiber	Cut-to-Length	4
12	Landing Gear Horizontal Tubes	1320	Carbon-Fiber	Cut-to-Length	2
13	Landing Gear Main Adapters	1330	Aluminum	Off-the-Shelf	4
14	Enclosure Hinge	2430	Zinc	Off-the-Shelf	2
15	Landing Gear Tube Joints	1340	PETG-CF	3D Print	4
16	Battery sliders	2200	PETG-CF	3D Print	2
17	BC PCB Cover	2313	PETG-CF	3D Print	1
18	Altitude Sensor Mount	2330	PETG-CF	3D Print	1
19	Enclosure Anchors	2420	PETG-CF	3D Print	4
20	Camera Mount	2320	PETG-CF	3D Print	1
21	Attachment Interface Spacer Left	2121	PETG-CF	3D Print	1
22	Attachment Interface Spacer Right	2111	PETG-CF	3D Print	1
23	Attachment Interface Spacer Bottom	2131	PETG-CF	3D Print	1
24	GNSS Mount Base	2341	PETG	3D Print	1
25	GNSS Mount Clamp	2342	PETG	3D Print	1
26	Main PCB Mount	2311	PETG	3D Print	1
27	Main Enclosure	2411	PETG	3D Print	1
28	Enclosure Top Cap	2412	PETG	3D Print	1
29	Enclosure Cap Clips	2440	PETG	3D Print	4
30	BC PCB Mount	2312	PETG	3D Print	1
31	Attachment Interfaces	2122	Aluminum	Off-the-Shelf	3

Table 2. Fasteners

Fastener ID	Fastener Description	Quantity	McMaster-Carr Reference
Rivet 1	4mm Diameter for 2.5 mm - 4.5 mm thickness	36	97525A251
Rivet 2	4mm Diameter for 4.5 mm - 6.4 mm thickness	10	97525A226
Screw 1	Socket Head Screw M3x10	48	91290A115
Screw 2	Flanged Button Head Screw M4x10	16	97654A373
Screw 3	Socket Head Screw M3x16	24	91292A115
Screw 4	Socket Head Screw M3x12	12	91290A117
Screw 5	Socket Head Screw M3x8	23	91290A113
Screw 6	Socket Head Screw M3x40	16	91290A136
Screw 7	Hex Drive Flat Head Screw M3x8	8	92125A128
Screw 8	Hex Drive Flat Head Screw M3x10	4	91294A130
Screw 9	Socket Head Screw M4x8	8	91290A140
Screw 10	Hex Drive Flat Head Screw M3x25	3	91294A138
Insert 1	M3 Threaded Inserts	50	97163A161
Insert 2	M4 Threaded Inserts	8	97163A153
Washer 1	General Purpose Washer 3.2 mm ID, 6 mm OD	158	98689A112
Washer 2	General Purpose Washer 4.3 mm ID, 9 mm OD	8	93475A230
Nut 1	Nylon-Insert Locknut M3	39	90576A811

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Preparation

Parts 1-3

• All three are aluminum 6 series sheets, laser cut, sanded.
• Bounding box dimension is 300x300x2 mm for each.

	Part 1 (Upper Plate)	Part 2 (Mid Plate)	Part 3 (Lower Plate)
Thickness	2 mm	2 mm	4 mm
Image
CAD File	Part 1	Part 2	Part 3

Parts 4-6

• All three are aluminum 6 series, 40x40x2 mm square tubes, laser cut, sanded.
• Part 5 and Part 6 are identical, order 2 parts for the same geometry.

	Part 4 (Cockpit Support Beam CW Long)	Part 5 & 6 (Cockpit Support Beam CCW Back & Front)
Length	289.2 mm	124.2 mm
Image
CAD File	Part 4	Part 5 & 6

Parts 7-8

• Both are aluminum 6 series, 1000x30x2 mm rectangular tubes, laser cut, sanded.
• Length is 300 mm for each.
• Parts are identical, order 2 parts of the same geometry.

	Part 7 & 8 (Battery Wall Left & Right)
Image
CAD File	Part 7 & 8

Part 9

• Off-the-shelf component.
• 30 mm option.
• 4 parts in total.
• Product Link: Link

Parts 10-12

• 30x2 mm circular carbon-fiber tubes with different lengths.
• Reference link: Link
  • Order 5 x 1000 mm or 10 x 500 mm

	Part 10 (Motor Arms)	Part 11 (Landing Leg Vertical Tubes)	Part 12 (Landing Leg Horizontal Tubes)
Length	360 mm	400 mm	500 mm
Quantity	4	4	2

Part 13

• Off-the-shelf component.
• 30 mm option.
• 4 parts in total.
• Product Link: Link

Part 14

• Off-the-shelf component.
• Part Number: GN 237-ZD-30-30-A-SW
• 2 parts in total.
• Product Link: Link

Parts 15-23

• All 3D printed parts.
• They have structural roles on the airframe. Use PETG-CF filament.
• STL link: Parts 15-23

Part	Quantity
Part 15	4
Part 16	2
Part 17	1
Part 18	1
Part 19	4
Part 20	1
Part 21	1
Part 22	1
Part 23	1

Parts 24-30

• All 3D printed parts.
• The parts should not interfere with GNSS signals. Use PETG filament.
• DO NOT use any filament containing carbon fiber.
• STL link: Parts 24-30

Part	Quantity
Part 24	1
Part 25	1
Part 26	1
Part 27	1
Part 28	1
Part 29	4
Part 30	1

Part 31

• Off-the-shelf component.
• Order without PCB.
• 3 parts in total.
• Product Link: Link

Tool List

• You need the following tools:
  • Allen key set
  • Wrench set
  • Cordless screwdriver or drill press
  • Riveting tool
  • Loctite Threadlocker Blue 242
  • Adhesive: Loctite Superflex Silicon Sealant Model 593, 6.4 fl. oz.
  • A cleaning agent to prepare the surfaces before adhesive

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Assembly Steps

Step 1. Assemble the Cockpit Support Beams on Mid Plate

• Parts needed:

  • Part 2 (Mid Plate)
  • Parts 4, 5, 6 (Cockpit Support Beams)
  • Rivet 1 x13

• Apply adhesive on the cockpit support beams around the holes on the contact side.

• Place the cockpit support beams on the mid plate as shown to the picture.

• Rivet the cockpit support beams from the mid plate on the holes shown in the picture.

  • Make sure you rivet before the adhesive dries.

Orientation	Adhesive Area	Rivet Holes

Step 2. Install the Battery Walls

• Parts needed:
  • Step 1 chassis
  • Parts 7, 8 (Battery Walls)
  • Rivet 1 x10
• Apply adhesive on the battery walls around the holes on the contact side.
• Place the battery walls on the sides of the chassis as shown in the picture.
  • Make sure the dented side stays on the chassis side.
• Rivet the battery walls from the mid plate on the holes shown in the picture.
  • Make sure you rivet before the adhesive dries.

Orientation	Adhesive Area	Rivet Holes

Step 3. Install the Motor Arm Connectors

• Parts needed:
  • Step 2 chassis
  • Part 9 x4 (Foldable Motor Arm Connectors)
  • Screw 1 x16
  • Screw 4 x8
  • Washer 1 x24
• Place the motor arm connectors on the chassis as shown in the picture.
• Secure the motor arm connectors on the chassis.
  • Use Screw 1 for red holes and Screw 4 for green holes.
  • Use Loctite Threadlocker.
  • Use Washer 1.
  • Use cordless screwdriver where possible, or else an allen key.

Orientation	Screw Holes

Step 4. Install the Lower Plate

• Parts needed:
  • Step 3 chassis
  • Part 3 (Lower Plate)
  • Rivet 2 x10
• Place the lower plate on the chassis as shown to the picture.
• Apply adhesive on the battery walls around the holes on the contact side.
• Rivet the lower plate to the chassis on the holes shown in the picture.
  • Make sure you rivet before the adhesive dries.

Orientation	Adhesive Area	Rivet Holes

Step 5. Install the Upper Plate

• Parts needed:

  • Step 4 chassis
  • Rivet 1 x13
  • Screw 1 x24
  • Washer 1 x24

• Place the upper plate over the chassis as shown to the picture.

• Apply adhesive on the cockpit support beams around the holes on the contact side.

• Rivet the cockpit support beams from the upper plate on the holes shown in the picture.

  • Make sure you rivet before the adhesive dries.

• Screw the motor arm connecters from the upper plate with Screw 1.

  • Use Washer 1.
  • Use Loctite Threadlocker.

Orientation	Adhesive Area	Rivet Holes

Step 6. Install the Battery Connector PCB Mount

• Parts needed:

  • Step 5 chassis
  • Part 26 (Main PCB Mount)
  • Insert 1 x20
  • Screw 5 x20
  • Washer 1 x20

• Place Insert 1 to the holes shown in the picture, on the top and bottom sides of the main PCB mount.

  • Use a soldering iron to place them inside the plastic.

Top	Bottom

• Place the main PCB mount over the upper plate.
  • Secure it with 5x Screw 5 in total from below the upper plate on the holes below.
  • Use Washer 1 for the holes.

Step 7. Install the Main PCB Mount

• Parts needed:

  • Step 6 chassis
  • Part 30 (BC PCB Mount)
  • Insert 1 x10
  • Screw 5 x3
  • Washer 1 x3

• Place Insert 1 to the holes shown in the picture, on the top and bottom sides of the BC PCB mount.

  • Use a soldering iron to place them inside the plastic.

Top	Bottom

• Place the Battery Connector PCB mount over the mid plate.
  • Secure it with 3x Screw 5 in total from below the mid plate on the holes below.
  • Use Washer 1 for the holes.

Step 8. Install the Battery Sliders

• Parts needed:

  • Step 7 chassis
  • Part 16 (Battery Sliders)
  • Insert 2 x8
  • Screw 9 x8
  • Washer 2 x8

• Place Insert 2 to the holes shown in the picture on both of the battery slides.

  • Use a soldering iron to place them inside the plastic.

• Place the battery sliders inside the battery compartment.
  • Be careful about the orientation of the angled end, they should point where the cutouts on the plates are.
  • Secure it with 8x Screw 9 in total from the sides of the frame.
  • Use Washer 2 with the screws.

Orientation	Installation Holes

Step 9. Install the Landing Gear

• Parts needed:
  • Step 8 chassis
  • Part 11, 12 (Landing Gear Horizontal & Vertical Tubes)
  • Part 13 (Landing Gear Main Adapters)
  • Part 15 (Landing Gear Tube Joints)
  • Screw 2 x16
  • Screw 3 x24
  • Washer 1 x56
  • Nut 1 x28
  • Screw 6 x4
• Place the landing gear main adapters below the chassis, as shown in the picture.
  • The adapters are facing outside to the left and right of the structure.
  • Screw the adapters with 16x Screw 2 to the chassis.
  • Use Loctite Threadlocker to secure the screws.

Orientation	Installation Holes

• Insert the vertical landing gear tubes inside landing gear main adapters.
  • Make sure the tubes are inserted all the way.
  • Tighten the clamps with the screws provided in the landing gear main adapter package.
  • Use Loctite Threadlocker to secure the screws.

• Make sure the chassis stands level on the ground.

  • If not, measure and equalize the tube lengths.

• Drill the tubes with 3 mm drill bit on the marked holes.

  • Use Screw 6.
  • Use Washer 1 on each side.
  • Use Nut 1.

• Assemble landing gear tube joints and the horizontal tubes as shown in the picture.
  • Insert the vertical tubes inside the holes before tightening the screws.
  • Use Screw 3.
  • Use Washer 1 on each side.
  • Use Nut 1.

Positioning	Installation Holes

Step 10. Install Side Attachment Interfaces

• Parts needed:

  • Step 9 chassis
  • Part 21, 22 (Side Attachment Interface Spacers)
  • Part 31 (Attachment Interfaces)
  • Screw 6 x8
  • Washer 1 x8

• Place and secure side attachment interfaces and the spacers as shown in the pictures.

  • Make sure the rectangular holes are aligned with the holes on the battery walls.
  • Use the screwdriver holes inside the battery compartment to place the screws and the screwdriver.
  • Use Screw 6.
  • Use Washer 1.
  • Use Loctite Threadlocker.

Positioning	Installation Holes

Step 11. Install Cockpit Enclosure

• Parts needed:

  • Step 10 chassis
  • Part 27 (Main Enclosure)
  • Part 28 (Enclosure Top Cap)
  • Part 14 (Enclosure Hinge)
  • Part 29 (Enclosure Cap Clips)
  • Part 19 (Enclosure Anchors)
  • Screw 1 x8
  • Screw 7 x8
  • Screw 8 x4
  • Washer 1 x8
  • Insert 1 x20

• Place Insert 1 to the holes shown in the picture from outside on the main enclosure.

  • Use a soldering iron to place them inside the plastic.

• Place the enclosure anchors and the main enclosure over the chassis.
  • The anchors will fit on the circular cutouts on the battery walls.
  • Mind the direction of the main enclosure.
  • Screw the anchors to the main enclosure with Screw 1.
    • Use Washer 1.
    • DO NOT use Loctite Threadlocker.

• Place Insert 1 to the holes shown in the picture from outside on the top cap.
  • Use a soldering iron to place them inside the plastic.

• Place the enclosure clips on the top cap as shown in the picture.
  • Screw the anchors to the main enclosure with Screw 8.
    • DO NOT use Loctite Threadlocker.

• Place the top cap over the chassis.
• Secure the enclosure hinges on the top cap and the main enclosure.
  • Use Screw 7.
  • DO NOT use Loctite Threadlocker.

Step 12. Install Altitude Sensor Mount

• Parts needed:

  • Step 11 chassis
  • Part 18 (Altitude Sensor Mount)
  • Screw 4 x4
  • Washer 1 x4
  • Nut 1 x4

• Place Insert 1 to the holes shown in the picture.

  • Use a soldering iron to place them inside the plastic.

• Secure the altitude sensor mount on the lower plate.
  • Screw head stays inside the mount.
  • Use Screw 3.
  • Use Washer 1 on the nut side.
  • Use Nut 1.
  • DO NOT use Loctite Threadlocker.

Step 13. Install Camera Mount

• Parts needed:

  • Step 12 chassis
  • Part 20 (Camera Mount)
  • Screw 10 x3
  • Washer 1 x3
  • Nut 1 x3

• Secure the altitude sensor mount on the lower plate.

  • Screw head stays under the mount.
  • Use Screw 10.
  • Use Washer 1 on the nut side.
  • Use Nut 1.
  • DO NOT use Loctite Threadlocker.

Step 14. Install Motor Arm Tubes

• Parts needed:

  • Step 13 chassis
  • Part 10 (Motor Arm Tubes)
  • Screw 6 x4
  • Washer 1 x8
  • Nut 1 x4

• Insert the motor arm tubes inside the motor arm connectors.

  • Make sure the tubes are inserted all the way.
  • Tighten the clamps with the screws provided in the motor arm connector package.
  • Use Loctite Threadlocker to secure the screws.

• Drill the tubes with 3 mm drill bit on the marked holes.
  • Use Screw 6.
  • Use Washer 1 on each side.
  • Use Nut 1.

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• The structural assembly is completed.
• Keep GNSS mount, GNSS mount clamp and BC PCB cover parts for the general assembly.