How to build a sub 250g 3.5-inch freestyle FPV Drone for $160

Embarking on the journey to build your very own 3.5-inch FPV drone is not only exciting but entirely achievable on a budget of just $160. Presented by Hoarder Sam, this guide takes you through each step of building a lightweight freestyle drone. Using parts sourced from Aliexpress, this project strategically keeps the total weight under 250g, thus avoiding FAA registration in the U.S. You’ll discover how to assemble and configure each component, from the Flyfish RC Volador VX 3.5 frame to setting up the intricacies of the Betaflight software.

Throughout the video, you’ll gain insights into creating a high-quality drone that mirrors the performance of larger, more expensive models but remains compact and efficient. The tutorial offers detailed instructions on choosing parts, assembling them, and configuring the electronics, ensuring you get the most out of your drone. Whether you’re a seasoned drone enthusiast or a curious beginner, this guide offers valuable tips, like upgrading motors for efficiency or setting video transmitter power levels for optimal performance. By the end, you’ll be ready to take to the skies with a drone that combines performance, affordability, and freedom from hefty regulations.

How to build a sub 250g 3.5-inch freestyle FPV Drone for $160

In this video, you’ll be guided through a step-by-step process to build your own sub 250g 3.5-inch freestyle FPV drone for less than $160 using parts sourced from Aliexpress.

Wiring diagram: https://i.ibb.co/SPTp6gP/wiringdiagra

Product links:

FlyFishRC Volador VX3.5 Frame: https://s.click.aliexpress.com/e/_Dlc

Alternate VX3.5 Frame: https://s.click.aliexpress.com/e/_Dd1

T-MOTOR 1604 Motors: https://s.click.aliexpress.com/e/_DEV

Alternate T-MOTOR Motors: https://s.click.aliexpress.com/e/_DFR

LANNRC 1505 Motors: https://s.click.aliexpress.com/e/_Dmi

YSIDO 1505 Motors: https://s.click.aliexpress.com/e/_DFh

Alternate YSIDO Motors: https://s.click.aliexpress.com/e/_DlL

SpeedyBee F405 Mini: https://s.click.aliexpress.com/e/_DCe

Alternate SpeedyBee F405: https://s.click.aliexpress.com/e/_DDG

Caddx Ratel 2 Camera: https://s.click.aliexpress.com/e/_DB5

Alternate Ratel 2: https://s.click.aliexpress.com/e/_Ddb

Cyclone 1W VTX: https://s.click.aliexpress.com/e/_DDR

SoloGood 1W VTX: https://www.aliexpress.us/item/325680

SpeedyBee TX800 VTX: https://s.click.aliexpress.com/e/_DEL

JHEMCU ELRS Receiver: https://s.click.aliexpress.com/e/_Dew

Happymodel ELRS Receiver: https://s.click.aliexpress.com/e/_DeP

HQProp T3.5 Props: https://s.click.aliexpress.com/e/_DeU

Alternate T3.5 Props: https://s.click.aliexpress.com/e/_DmZ

RadioMaster Pocket Radio: https://s.click.aliexpress.com/e/_Dm2

Eachine EV800D Goggles: https://s.click.aliexpress.com/e/_DEz

Tattu 4s 650mah lipo battery: https://s.click.aliexpress.com/e/_DlW

Pinecil Soldering Iron: https://s.click.aliexpress.com/e/_DBJ

TS100 Soldering Iron: https://s.click.aliexpress.com/e/_DBG

Hota D6 Charger: https://s.click.aliexpress.com/e/_DDX

Table of Contents

Understanding the Project

Objective: Building a Sub 250g 3.5-inch Freestyle FPV Drone

Building your own sub-250g 3.5-inch freestyle FPV drone can be a rewarding and educational project. With advancements in technology, accessible materials, and comprehensive tutorials, such as this one by Hoarder Sam, creating your own drone is now more achievable than ever. The objective of this project is straightforward: to assemble a lightweight drone capable of freestyle flying, capturing thrilling footage, and avoiding the hassle of FAA registration, all while keeping the assembly process engaging and enjoyable.

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Cost Efficiency: Keeping Within the $160 Budget

Budget is a significant factor when embarking on any DIY project. In this tutorial, we aim to build this sleek and agile flying machine while keeping costs under $160. By carefully selecting cost-effective components from platforms like Aliexpress, we ensure that the project remains accessible without compromising on quality or performance. Saving on materials doesn’t mean cutting corners but rather opting for the best value and efficiency in our component choices.

Sourcing Parts from Aliexpress

Aliexpress is a renowned online marketplace offering a vast array of electronic components and accessories suitable for drone enthusiasts at competitive prices. It presents an opportunity to source essential parts for this project economically. By tapping into the diverse offerings on Aliexpress, you’ll be able to gather every part required to bring your drone to life, making it a go-to resource for hobbyists and seasoned builders alike.

Presented by: Hoarder Sam

This project is presented by Hoarder Sam, a passionate drone enthusiast with a knack for creating engaging, budget-friendly tutorials. Sam’s guidance will illuminate each step of the build process, ensuring that even those new to drone assembly can follow along with confidence.

Overview of the Drone Specifications

Propeller Size and Drone Weight Specifics

The drone we are focusing on in this project is designed around a 3.5-inch propeller size, which is crucial for its light build and agility. The total weight of the drone, including the necessary 4S 650mAh battery, remains just below 250g. This lightweight design is pivotal, as it exempts the drone from FAA registration in the United States—a major boon for hobbyists who prefer minimal bureaucracy.

Exemption from FAA Registration

In the U.S., drones weighing over 250g are required to undergo registration with the FAA. This drone’s weight-conscious design strategically skirts these regulations by staying under the weight threshold, which makes it a perfect choice for casual flying and exploration without the extra steps of regulatory compliance.

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Comparison with Larger 5-inch Freestyle Drones

While 5-inch freestyle drones have long been the standard, the 3.5-inch version offers many of the same flight characteristics, but with reduced noise and increased efficiency. Despite being smaller and lighter, this class of drone provides a similar flying experience, making it a convenient alternative for enthusiasts, especially those flying in urban or noise-sensitive areas.

Recommended Parts List

Flyfish RC Volador VX 3.5 Frame

The Flyfish RC Volador VX 3.5 frame is the foundation of our build. Priced reasonably, it offers premium features like aluminum side plates for camera protection and soft mount inserts for flexibility in camera choices. The frame’s compatibility with DJI’s 03 Air Unit also makes future upgrades easy.

Yido 1505 Motors

For propulsion, we recommend the Yido 1505 motors. Offering a balance between performance and cost, these motors come in two KV values. For this tutorial, the 2650KV motors are chosen to enhance efficiency without sacrificing too much thrust, ideal for standard freestyle maneuvers.

Speedy B F45 Mini Flight Controller Stack

The heart of the electronic setup is the Speedy B F45 Mini flight controller stack. Known for its integration of useful features, including Bluetooth configuration, this stack allows for easy setup and tuning via a smartphone, providing a user-friendly experience typically associated with much higher-priced stacks.

Cadex Ratel 2 Camera

A robust camera is essential for capturing crisp footage during flight. The Cadex Ratel 2 is chosen for its quality and the practical layout of its wires, which facilitate easy installation in the compact frame. It provides excellent video clarity, even in varied lighting conditions.

Additional Necessary Components

Apart from the core components listed, additional items such as a Solo Good VTX, an ExpressLRS receiver, an appropriate battery, and optional accessories like analog goggles and high-quality soldering tools are necessary to complete the build. Each component has been selected to complement the overall performance, contributing to a seamless building and flying experience.

Frame Assembly Process

Step-by-Step Assembly Instructions

Begin by laying out all your components for easy access. Start by assembling the frame per the instructions provided, ensuring each screw and component is securely fitted. Patience at this stage will pay off significantly as it sets the foundation for the rest of the build.

Mounting the Components on the Frame

Once the frame is secure, proceed to mount the flight controller, motors, and camera. Pay attention to orientation and spacing, as compact environments require precise installation to avoid conflicts and optimize balance.

Ensuring a Secure Build

Verify each component’s integrity and alignment by ensuring all connections are tight and secure. A completed assembly should withstand light pressure without any parts shifting. This careful checking prevents potential failures during flight.

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Wiring and Soldering

Detailed Wiring Guide

The wiring phase involves interpreting drone schematics to connect components like the flight controller, ESC, motors, and camera. Follow detailed diagrams to ensure connections are accurate, which is crucial for functionality.

Soldering Techniques for Drone Components

Soldering is a skill that impacts the drone’s reliability. Use a quality iron for steady heat control, apply flux to facilitate smooth soldering, and ensure each joint is clean and shiny. Proper soldering prevents disconnects and ensures long-lasting connections.

Troubleshooting Common Soldering Issues

In soldering, issues like cold joints or excess solder can arise. If connections are weak, reheating and applying flux can often resolve these problems. Troubleshooting at this stage prevents operational issues and keeps the build process on schedule.

Firmware Updates and Configuration

Upgrading ESC to BlueJ for Performance

Updating your Electronic Speed Controllers (ESC) to the BlueJ firmware can improve performance metrics like throttle control and power efficiency, translating into smoother flights.

Betaflight Configuration for Firmware

Betaflight offers comprehensive configuration options for tweaking drone settings to achieve desired flight characteristics. Ensure you keep your firmware updated for the latest features and improvements.

Loading VTX Table for Configuration

Load your VTX table appropriately to facilitate video transmission. Proper configuration ensures that your drone transmits clear, interference-free video signals during flight, crucial for mitigating possible signal loss.

Receiver Setup and Betaflight Configuration

Step-by-Step Receiver Setup

Setting up your receiver correctly is paramount. Ensure that it is securely mounted and wires are neatly routed. Binding the receiver correctly with your transmitter is necessary for operation.

Configuring Betaflight for Optimal Performance

Betaflight allows for detailed configuration to fine-tune performance. Options such as PID adjustments, flight modes, and rates setup should be carefully looked into to adapt the drone to your flying style.

Setting Default VTX Settings

Setting up your VTX with defaults that prevent overheating or signal loss is important. Configure settings like band, channel, and power output to meet your flight objectives and environmental conditions.

Customizing the On-Screen Display (OSD)

Switching from HD to Analog

Determine whether analog suits your setup better than HD to optimize compatibility and functionality. While HD provides clarity, analog can offer better resolution with specific setups.

Preference for PAL Mode Over NTSC

Choosing PAL mode can sometimes yield better resolution and frame rate than NTSC, depending on your regional and equipment compatibility. Experiment to find the best fit.

Adding Essential Flight Data to OSD

Integrating critical data like battery voltage, artificial horizon, and timer information into your OSD provides real-time feedback that enhances flight control and safety.

Flight Preparation and Configuration Adjustments

Pre-flight Setting Configurations

Before your maiden flight, double-check settings such as flight modes, OSD layout, and safety features. These checks ensure that everything operates smoothly during takeoff and flight.

Customizing Motor Settings

Adjust motor settings according to your drone’s specifications and weight class to optimize performance. Correct calibration results in a responsive, balanced, and enjoyable flight experience.

Verification of the Motor Order and Direction

Verify that your motors are spinning in the correct order and direction before flight. Use configuration wizards to adjust any discrepancies, ensuring proper stabilization and control during flights.

Conclusion

Summary of Building a Cost-effective, Lightweight FPV Drone

In this project, you’ve built a capable and cost-effective 3.5-inch freestyle FPV drone that offers exhilarating performance without the complexity of larger builds. Its lightweight nature, along with careful component selection and economical design, makes it a rewarding venture.

Encouragement to Explore More Content and Tutorials

This tutorial is just the beginning. Dive deeper into the world of drone building by exploring more tutorials, joining community forums, and experimenting with different configurations and upgrades as your skills grow.

Final Tips and Considerations for Successful Flight

Understanding your build, consistent practice, and an inquisitive mindset are key to mastering drone flying. Remember to check your settings before every flight, stay informed of local regulations, and fly responsibly for a safe and enjoyable experience.