Sonicmodell AR 600 Mini Aerodynamic Bicam Kit by Mateyhv

Last crawled date: 3 years, 3 months ago

14/11/2020 EDIT. List of changes: 1- Reworked Nose section to avoid dark corners on Loris HD; 2- Added three Winter Operations air inlets for reduced cooling; 3- Added forgotten Cutting Stencil stl; 4- Added Printing Aid and picture for printing the Motor Firewall in Cura. 5- Added a few more pics. 6- Text and namings rearranged.
Complete aerodynamic kit for upgrading the Sonicmodel AR 600 Mini. The goal is to install the Caddx Loris 4K side by side with the Runcam Micro Eagle 2 for nice FPV and also to improve tail aerodynamics although the belly bump for example can be used standalone. The mod uses a stock foam nose which can also be bought separately, a quad 2205 motor (16x16mm screw hole distance on stand) plus 3x M2 screws and (optional) 8x 1mm insulating spacers, Everything else is 3D printed.
Weights are given in PLA/TPU although here is a list of some other materials:
PLA: rigid up to ~60ºC hard (in some cases easier to break), slightly heavier than the rest.
PETG: rigid up to ~80ºC, some degree of flexibility, slightly lighter than PLA.
ABS: rigid up to ~105ºC, hard, slightly lighter than the rest. Prone to warping.
TPU: flexible filament, for accessories and caps.
All parts are printed with 0,42mm wall line width.
Parts List

Nose uEagle2 Loris4K:
Extends the foam nose, keeps aerodynamic profile, moves cameras forward to maintain CG, improves cooling and reduces front cross section. Specifically for Runcam Micro Eagle and Caddx Loris 4K. Eliminates bullseye effect on both cameras.
Remove the center foam section by previously marking with the stencil (see Cutting Stencil bellow). Mount the cameras carefuly flexing the pilars to make them fit. Sometimes the pilar breaks so be prepared to print the nose section again. Test the cameras and only when fully ready apply a small amount of glue to the flat tabs and insert the assembly into the foam nose.
PETG good, ABS ok, PLA ok.
layer height: 0,15mm
walls/top/bottom: 2
infill: 16-20%
Rise printing temp 10ºC to improve layer adhesion for stronger and more flexible pilars.
Weight: 4,25gr


Nose uEagle2 Loris4K Cutting Aid:
Used as a stencil to mark the cutting line on the original foam nose. Place the side tabs just inside the foam rim and press so the foam gets marked. Cut the marked section with a very sharp blade and be conservative, you can always expand the hole later to fit the new nose with the cameras.
PLA, PETG and ABS are all OK.
Choose your preferred settings.


Loris Board Stands (Upper and Lower parts):
A couple of stands are fitted into the opposite sides of the board screw holes to maintain it stuck into the horizontal foam slot between the nose and the battery compartment. Insert the board diamond-like leaving the SD card and the REC button exposed. The big nose air inlets will keep good cooling.
ABS good, PETG and PLA ok. The board reaches 60ºC+ degrees on the ground although I haven't seen the PLA stand been affected so far.
layer height: 0,2mm
Weight (one couple): 0,15gr


Lens Cap Bicam:
For transport protection.
TPU (flexible) only
layer height: 0.2mm
walls: 2-3
top/bottom: 2-3
infill: ~80%


Lens Cap Loris only:
Protects only the 4K lens on landings when camera is not in use.
TPU (flexible) only
layer height: 0,2mm
walls: 2-3
top/bottom 2-3
infill ~80%
weight: 0,56gr


Belly Bump:
Used to streamline the finger bump on the lower fuselage. For printing position the flat side against the bed.
PETG, ABS, PLA are all ok.
layer height: 0,15mm
walls: 1
top: 1 / bottom: 2
infill: 0%
weight: 0,95gr


Motor Firewall:
Features full size ventilation port, wings trailing edge, 3 attachment points (2mm screw) for the tail cone.
Attach it to the wing with the original four screws. The holes might be slightly displaced due to manufacturing inconsistency, you can easily expand them with a hot rod aplied to the printed material. The tiny wings must be hollow to reduce weight. Can be done in Cura using modifiers and a square object, see part 5 ;-)
PLA, PETG and ABS are all good.
layer height: 0.15mm
walls/top/bottom: 2
infill: ~20%
wings infill: 0%
weight: 4,05gr


Motor Firewall Printing Aid:
To achieve the Motor Firewall with hollow wings in Cura use a pair of printing aid cubes (see pictures). Place them overlapping the wings and selecting Mesh Type menu (fifth icon on the left hand side toolbar) -> 'Modify settings for overlap'. Select 0% Infill. With the same method you can change other parameters if you wish.


Tail Cone versions A and B:
Enlarged streamline shape, internal ventilation ports for cooling.
Version A is intended for use with 8x 1mm heat insulating spacers for the motor screws so that heat transfer over the printed material is reduced. If you don't have anything suitable you can print version B wich keeps the same geometry without spacers.
PETG or ABS, flexibility and heat resistance are both intersting. I don't have problems using PLA with version A cone because I am mainly cruising and motor keeps cold.
layer height: 0,15mm
walls: 2
top/bottom: 2-3 (affects weight and mostly the hardness of the motor base stand)
infill: 35 - 50% (high numbers needed mostly for the flat motor base printing)
Weight: 7,35gr


Winter Operations Air Inlets:
For those who fly in cold weather reduced cooling air Nose flow will maintain battery warm for better performance and will also protect the inlets from snow/debris. Available in three sizes, Medium, Small and Closed.
-TPU (flexible) only
layer height:0,2mm
walls: 2
top/bottom 2
infill 20-50%
weight: Medium 0,47gr, Small 0,52gr, Closed: 0,51gr


AR Mini Keychain Badge:
If you have ended up at this point you definitely deserve the greatest AR Mini pilots keychain badge :-) Looks like its for Inav users. "AR Mini" text is stamped on the reverse. Print from whatever material you like with your preferred settings and if you want to up/downscale it just do it on the X and Y axis since Z will mess up with details.
layer height: 0,2mm

ENJOY!!!