Are you tired of broken battery tray wire holders?

[override]

If anyone else around here is like me then you have had your share of problems with the 3D printed battery tray wire holders breaking on you. The wires always pull through the sides on mine and since I live in the states and have no access to a 3D printer waiting on parts gets tiresome. Well if you happen to have a broken battery tray and some wire holders laying around then you may just be in luck 🙂

I took my broken battery tray and hacked it up to make some G10 copies of the 3D printed parts. Currently I am just simply using them as reinforcement.

Tools you will need:
Dremel
Cutting Wheel
Sanding Wheel
Engraving Cutter (optional)
Diamond Wheel Points (optional)
Hand Drill
Cordless Drill (optional)
7/64″ Drill Bit
2mm hex and 5.5mm wrench
(2) screws with nuts
G10 Camera/Battery Tray
3D Printed Top Wire Holders

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03956_zpszhaiwgyy.jpg

Take your top wire holders and line them up on your battery tray, using your hand drill mark your holes.
http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03955_zpsw2uw5e7s.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03957_zpsoalstwun.jpg

Drill your holes out.
http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03958_zpsjizqxvnh.jpg

Bolt the two pieces together and using your cutting wheel make a rough cut the shape of your top wire holder.
http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03960_zps910ksxry.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03961_zps9ekgohhn.jpg

I recommend wearing some sort of mask as when your shaping the part G10 dust will fly everywhere. Using your sanding wheel, grind of the excess from your rough cut.
http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03962_zps52ggzeml.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03963_zpsymjno3l5.jpg

Repeat the process for the other top wire holder.
http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03964_zpskgehhet9.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03965_zpsgjzifezk.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03966_zpsl5imrlpg.jpg

Now simply bolt these down on top of your 3D printed parts. Use thread lock if you don’t replace the bolts with slightly longer ones. Your all finished!

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03968_zpsl5eutdes.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03970_zps6emqbvn6.jpg

Optionally, if your battery tray isn’t broken at one of the wire grooves, you can simply cut each piece out over the grooved parts and use just the G10 in place of the 3D printed parts. This may possibly cause more breakage in the end though since you don’t have any plastic to give. If you do decided to go this route and have dried CA glue you can used the Engraving Cutter and Diamond wheel point to clean out the CA in the grooves.

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03946_zpsw3spudyr.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03948_zpsruelgzap.jpg

http://i621.photobucket.com/albums/tt295/dpg_override/Tri%20Copter%20V3/DSC03952_zpsolut3trh.jpg

I do not take responsibility for any injuries while performing this task, please take caution to wear safety equipment. As well this goes for any damage done to your tri in a resulting crash, since you are reinforcing these 3D printed parts, if the G10 cut outs don’t give then something else more critical very well may.

Thanks and Hope this helps,
override

[marcoose]

If you have access to a mill I just cut some out of solid plastic

Attachments:

1. 

   milled_wire_holder.jpg
   

[override]

Yeah unfortunately I don’t have access to a mill either 🙁 I wish I had some of the wonderful toys to create stuff. Although that’s why I made this post, for people such as myself that want cheap rigity. I have had several crashes since I made these reinforcements and the most I ever have to do is bent the battery tray wires back to shape. No more broken plastic parts!

[Agent CAL]

Looks cool, maybe I’ll try it out!

[Wouter]

Could I also make it from plywood?

[Wouter]

Update: i think it is also possible with my leftover tricopter frame (i got the power distribution frame and i am verry happy about it) please tell me if it is not a good idea, or if i should use two on top of each other or anything else.
Thanks
Wouter

[override]

You can use whatever material you see fit, even the left over frame if you want too. The only thing I could think on the frame is its thin, so it could eventually crack. Whatever you decide to use though just mind the thickness of it as far as your screw length/battery space.

I just realized this thread got stickied, awesome and thanks! 🙂

[override]

Oh wait a minute, no it didn’t, my mistake. Lol

[Author]

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