Balls of Steel Build Thread

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First things first
I'd like to thank CK from Ritewing for designing, cutting and pre-building this plane for me. It has been a long-time dream of mine to own a beast like this, CK has helped make it a reality. I'd also like to thank HK for a generous donation of a set of batteries, some servos and ESC. Unfortunately the ESCs died in a water crash along with some servos, rule dictates all 4 servos need to be identical so we switched to Graupner post-crash. In any case, thanks also to IRC for sending some love! You guys rule!

Balls of Steel material list
CK at Ritewing
1x custom BoS wing kit (comes with elevons, winglets, material for vortilons, etc)
2x Rocket Motor Inrunners
8x 9x5 pusher prop counter rotating (4x left, 4x right)
30x glass fiber spars with 15 joiners
10x glass fiber strips

HobbyKing
4x 6000mAh 3S nano-tech (wired to 2x 6S 6000mAh)
1x 35MHz Corona 8ch Dual-conversion
10x Servo extensions

TBS
4x Zephyr Graupner Servos
2x Graupner ESCs
1x TBS 69 + TBS PSU
1x custom GoPro 3D mount
1x lawmate video
1x IRC LRS

GoPro
GoPro Hero and 3D cable

RangeVideo
RVOSD G5

Small bits & pieces were bought at the local hobby shop (pushrods, servo horns, etc). Glues were already on site (3M90, Gorilla Glue, CA, hotglue). Overall build time was 2 months on and off, it took about 4 days in total to complete to maiden. Lots of modifications were done from then on, right now it flies somewhat reliable. The wing is like a Zephyr, except a lot more floaty. Stall characteristics are good, but she wants to travel. Reactions are pretty quick at speed, she is not permanently controllable though (e.g. when you hit the crow brakes too hard the elevons stall waiting for you to retreat crow). Landings are a breeze, she floats like a true champ I think I could thermal her all day. When you crank the throttle a tingling sensation is happening in your pants. That speed is unbelievable. The sound of the twin motor is breathtaking to say the least, but a little too loud for everyone else's taste. For me it's just right

Specification:
Max level speed: 201kph
Max duration flight: 35mins
AUW: approx. 7kg, haven't weighed it yet

Collection of Maiden & Test flights:

View this video on YouTube

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Today I started with the build. Impatient as usual, I did the stuff that requires very little brainwork. The spar system.

7 main spars, 3 spars further up the middle. Glued in with Gorilla Glue, babysitting and wiping off excess Gorilla Glue kept me from taking more pictures. Once everything looks settled down it goes back into the wingbeds to keep everything straight and true.

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And in the second half of the day we prepare the motor with motor mounting brackets, and glue on the wingtips.

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Some more pictures for adding the motor mount. Next step will be to do the equipment layount and then spars.

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Installing the spars with a specially-modified soldering iron and gorilla glue.

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... and some more progress on the surface spars. Add a lot of gorilla glue, let it foam up, cut it off later. It looks really bad at first, but after cutting you will see the benefit of having Gorilla all foamed up.

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Just one pic for that step ... dirty floor!

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We drill two holes next to the DEANS on each side, and fill 'em up with Epoxy. That way the cables are super-strong. A dummy-plug is used to secure on the other side. Mhhhh, Epoxy!

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Overview of the Zephyr with 80A Plush ESCs installed (exchanged later for 70A Graupner ESCs). And then some pictures of the custom-designed 3D GoPro mount. The 3D cable from GoPro was modified in order to fit the wider distance of the lenses. won't be shown but it's pretty easy to do: just open the screws on the back you should get the gist of it immediately.

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Since I can't use the RVOSD G5 PSU for my 12V camera (it passes through the 22.2V from the 6S), I'm gonna use the TBS PSU. It needs a little special wiring ... no VCC from the RVOSD to the camera, but a direct connection from the TBS PSU to the camera for VCC. the rest is fairly standard.