The QAV540G quad airframe with integrated brushless gimbal is now available for pre-order and has an expected ship date of the “2nd half of June”. Also available for pre-order is the new brushless gimbal upgrade for the QAV500 quad airframe. The QAV500 quad airframe has become the airframe of choice for top quality FPV pilots and even many commercial aerial videographers due to its compact size and vibration free video performance. The QAV540G and the gimbal upgrade for the QAV500 push the QAV500 into the brushless gimbal revolution by integrating a brushless gimbal directly into the airframe.

Footage of the QAV540G

Footage of a QAV500 with Brushless Gimbal Upgrade

The QAV540G and QAV500 with Brushless Gimbal Upgrade provide 180 degrees of unobstructed tilt view (up/down)

I want to show you the current status of fpvmanual’s new frame prototype — the QAV540G. The QAV540G combines the stability of the QAV quad series with a fully integrated brushless gimbal for a GoPro 3. The frame will not show props in view even in extreme flight angles (disclaimer: more testing needed to confirm this statement to be true under all conditions). The below video shows some of our early test footage. There are still things to iron out and the frame will likely still change in a few spots — but overall, I think we’re close enough to get your feedback.

Many videos that demonstrate camera gimbals and their efficacy fly the airframe in a super agressive way. In this video, I chose to fly the quad how I would always fly it to produce clean video — smoothly. This enables the gimbal to have to do the most minimal amount of work to smooth out the remaining wobbles that a non-gimbal airframe will show in the footage.

We will provide more details as we get closer to release date (such as pictures of the frame). I wanted to make this announcement now to let everyone know that we are hard at work to provide one of the first airframes that will come with an integrated brushless gimbal.

Some details

• The frame has to carry a gimbal and a 5000mah 4s to counter balance the weight due to the way we structured the frame. This means that the QAV540G will be… heavy
• The gimbal is produced to fit a GoPro 3 and only a GoPro 3
• Max prop size: 11″ prop
• The frame will be sold with the gimbal and most likely with the appropriate gimbal motors — but not with a BGC board or other electronics
• Release date: still ways away, unfortunately
• Price: TBD

The video shows all raw footage. No slow motion effect or post processing / stabilization was applied. One clip was reversed as it was flowing better with the edits.

UPDATE 4/15/2013

Here is a new video with additional flight footage and some test footage.

I am now happy to announce that OP and fpvmanuals have collaborated closely to release the CC3D ‘fpvmanuals edition’, now on sale in the US at getfpv.com retailing for $98.94. The board was produced under guidance from OP using high quality components and a professional assembly facility. The board should perform identically to boards produced by OP. Each board is tested by fpvmanuals prior to shipping.

I would like to thank David Ankers for his support and guidance during the production of this CC3D.

Order Now

Highlights

- Fully assembled and tested CC3D board pre-loaded with the latest firmware
- Retail price of $98.94 with free 2-day shipping in the USA for a limited time
- The board is branded with the fpvmanuals logo to make it easily identifiable
- The board is produced in white, the new board color for OpenPilot
- Each board ships in professional packaging and comes with a receiver cable and OP serial cable

To get started with your CC3D board, visit the OpenPilot Wiki.

Example videos flown with the CC3D

Extreme Acrobatics
Pilot: Juz
Frame: QAV400

Smooth lines without a gimbal
Pilot: MidwestRob
Frame: QAV400

One of the most severe and overly broad laws is being crafted in the state of Oregon with the proposed Senate Bill 71. Help stop this particular bill by signing this petition at Change.org. This petition needs another 400 signatures and I am sure that we can help them get there.

https://www.change.org/petitions/oregon-senate-bill-71-protect-the-rc-hobby-aerial-photography-and-fpv-communities

Also, join the discussion about the threat of “drone legislation” at FPVLab

What it is we are looking to protect:

Watch this informative video put together by RCModelReviews out of Australia.

• Please read this manual all the way through first to decide how you would like to build the model. There are two ways you could go about building. First, is to fully build the model to get an overall perspective of what it will feel and look like, the down side to this is you would have to then disassemble a small amount to put in the electrical components. Second, is to build in the electronics as you build the model. This manual uses the first method, but has electronic build instruction images and instructions placed in the appropriate areas.
• Best if QAV400 is built on a hard flat surface so as to not let any of the frame plates flex while bolting.
• The frame is always flown in “X” configuration. Make sure you switch/set your FC to fly in “X” mode.

Parts List

Check your package contents to make sure you have all the parts. Your parts may show some scuff marks or minor scratches. That is expected and nothing to worry about.

Some tools that will help your build run a little smoother. A 7/32 socket, the included 2mm allen wrench, needle nose pliers, and importantly, blue thread locker. Only use blue (non permanent) thread locker. Try to let the thread locker harden over night. You will also need all of the tools associated with soldering, and anything else needed for your electronics.

Frame Assembly “Dirty Section”

• Parts needed: The four black aluminum motor arms, 16 of the button head screws, PCB Plate. Tools needed: Allen wrench and thread lock. Whether using method one or two to build the frame, these screws will not have to be taken back out, so thread lock each screw.
• As shown below, place the PCB frame plate with the electrical pads facing down. Then place the motor arms next to the frame flat sides facing up, and the wire grooves facing down.
• See next image…

• Slide the arms underneath the PCB Plate and align the bolt holes with the outer 4 bolt holes, then apply thread lock to the screws and fasten them. The 2 images below show correct placement.

• The 3 images shown below are for reference only, and shows other capabilities of the QAV400 frame.
• Now, maybe you noticed the extra screw holes closer to the center frame near your screws. In fact, if you are a QAV500 owner, then maybe this other screw pattern looks familiar. Below you can see the ability of placing the QAV500 motor arms on the QAV400 frame. This gives the QAV400 the capability to run 10″ props instead of 8″ props supported by the black QAV400 arms.

• Next, we put spacers on the PCB plate. You will need 9 button head screws, and 9, 10mm spacers. Make sure you use your thread locker again, as you won’t have to remove these again.
• The 2 images below show the correct placement, and screws pointing to the holes used.
• Also, see the illustration for the location of the frame’s Center of Gravity.

• If deciding to build the electronics while you go, then follow below.

ESCs

Take the power distribution board (“PDB”) and solder the ESCs to the connections marked by “ESC1″ through “ESC4″. Please note that this is how the QAV400 numbers its ESC. This numbering will not match up with how a flight controller numbers the motors. Make sure you solder all the red wires to the “+” pads and all the black wires to the “-” pads. You want the power cables to be fairly short. Take a look at the picture below. The best way to assemble the motor/esc is by soldering the motor cables directly onto the ESCs. This will save you a lot of build time if your motors and ESCs don’t already come with bullet connectors. It also will remove one of the key failure points on any multi-rotor. Bullet connectors can loose connectivity mid flight or one of the many solder connections that bullet connectors introduce can get weak and fail. If you do solder the motor wires straight onto your ESCs, make sure you shorten/lengthen your motor cables to an appropriate length and that you test each ESC/motor to ensure the motor spins in the right direction for where it will be located on the frame.

Lipo Pig-Tail

Solder a lipo pig-tail to one of the pads with the “Bat1″ or “Bat2″ labels. Turn the PDB so that the pig-tail comes out on the side that will work best with your lipos. If your lipos have the power leads on the right side, make sure the pig-tail comes out on the right side as well. You can attach the pig tail with a zip tie to the PDB. This ensures that in the event of a crash the pig tail will not be ripped off the pads and damage the PDB.

Other Power Leads

The PDB of the QAV400 provides you many additional power pads. Use these to attach power leads for your FPV equipment, lipo meters, sensors, cameras, LEDs, etc.

Vibration Mounts (“Orange RC Bobbins”)

• The vibration mounts are what separate the “dirty” section and the “clean” section. They are a vital part of the proper functioning of the QAV400 frame.
• You will need 4 of the Orange Vibration Bobbins and 4 M3 nuts, your 7/32 socket and thread locker. The mounts will be placed on the two front and two back holes located on the PCB frame plate.
• The 2 images below show correct placement.
• When tightening the nuts, make sure you do not twist the orange vibration material, it can sheer off! Use a bit of thread lock on the threads of the studs to secure the nuts.

Frame Assembly “Clean Section”

• To assemble the bottom plate of the “clean” section we will need the longest plate in the build kit, 8 of the 35mm aluminum spacers, and 8 button head screws.
• The screws point to their respective holes of placement in the image below, along with the following image showing them installed.
• These are screws that you can add the thread lock to now and not have to worry about unscrewing again.

• The next step is to attach the section we were just working with to the “dirty” section of the build via the orange vibration mounts. But, if you are building the electronics as you go, then take a look at the 2nd image below. It would be a good time to attach your Flight Controller to our long base plate of the “clean” section. Included in the kit is a strip of sticky sided foam that you could use as a base, or use standoffs in one of the provided mounting hole patterns. Shown in the second image is a CC3D flight controller that is mounted via 4 nylon standoff spacers (not included). Make sure your FC is centered on the Center of Gravity, and evenly centered between the holes.
• 
• You can also bring the ESC signal and power wires up through the center slot of the base “clean” section plate, or any hole towards the front of the plate. The holes toward the back will be covered by your Lipo.

• After securing the FC and connecting the ESC wires it is time to secure the last 4, M3 nuts onto the orange vibration mounts.

• Lastly, it is time to install the top plate of the “clean” section. Which consists of the short G10 plate and 8 button head screws.

• That’s it for the frame assembly!

Placing your lipo and optimizing Center of Gravity

The lipo is secured to the frame with the use of the included ‘fpvmanuals’ lipo strap. The included lipo strap is a special rubberized strap that does not require you to use use any velcro stuck to the frame or your lipo. You want to avoid using velcro as it would require you to rip your lipo off your frame when you want to swap lipos. This forceful removal of your lipo when using velcro can damage the vibration bobbins. The use of this high-end strap makes lipo changes quick and easy and also protects your frame and vibration bobbins.The lipo is placed on the back of the frame either into the cavity between the long “clean” base and the flight controller cover, or on the top of the flight controller cover. The Lipo is used to adjust your center of gravity most importantly. By picking up your QAV400 by the top cover, in the center of your FC you can check the balance. If the 400 tips to the back then slide the Lipo forward till it is corrected. If it still will not center then place the Lipo on the top plate and move the strap there to secure it. Now adjust again to balance.

Completed overall reference images

• If there is any confusion or questions about the build or any compatible parts with the QAV400, the official thread is found here at fpvlab.com

Size and build comparison to the QAV500

Optional Accessories – Carbon Fiber Landing Gear

• The Carbon Fiber Landing Gear can be found here at the getfpv.com store.

If you purchased the optional Carbon Fiber Landing Gear, please see the below picture on how to assemble it and attach it to the arms. It’s important that you apply even force on each of the two set screws. Also, take care not to over-tighten the set screws with the included allen key. The clamps holding the carbon fiber tubes are made of aluminum which is a soft material that can easily strip.

Delrin Landing Gear

• The Delrin Landing Gear be found here in the Getfpv.com store

After we released the first LayerLens for the GoPro 3 I noticed a number of issues that slipped by me during testing. I recalled the product and offered everyone their money back. It was a major set-back. We started the re-design process from scratch to address all the minor and major issues we encountered. During this process we changed almost everything:

• We chose a new lens holder material to make it lighter and tougher
• Created a new lens design and material to perfect image quality
• Changed the overal dimensions to ensure no part of the bezel will enter recorded video or camera resolutions
• Changed away from laser-cutting to high quality CNC machining to improve how the lens is secured and reduce overall parts count, which makes assembly a snap
• Reduced the total weight down to 7.5g for the fully assembled LayerLens

The new ‘rev 2′ of LayerLens for the GoPro 3 is now finally done and I am excited to be able to offer it. I know many of you have been waiting for this. I heard from some that they were not using their GoPro 3 out of fear of scratching it up while flying without a LayerLens. Many resorted to flying their GoPro 3 with the stock case to protect their lens in the meantime.

The new LayerLens comes with a lens that I spent a long time tweaking and perfecting. After many iterations of testing and re-testing, we choose a lens that has a hard coating layer and an AR (anti-reflective) coating on both sides of the lens. This ensures that almost 100% of the light that hits the lens passes through and reaches the GoPro’s processor — after it passes through the AR coated lens of the GoPro 3. The included lens also has an ‘anti-smudge’ coating on the ‘viewing’ side — the outside facing surface of the lens — to minimize finger printing.

We hope that you will be able to make good use of this new version.

Available at GetFPV

Lens care

To care for your lens, make sure you clean it with a suitable lens cleaning solution and soft microfiber cloth — the same type of solution and cloth you would use to clean eye glasses. Never use ammonia based cleaners such as Windex as that will ruin the AR coating on the lens.

The new fpvmanuals QAV400 FPV quad frame starts shipping as of today, February 8th, 2013 world-wide. We look forward to seeing amazing videos from our global pilot base. Enjoy!

Available at http://www.getfpv.com/qav400-frame.html

FPVM: First, what do you do when you’re not flying FPV?

JUZ: When not flying, or working as a ranger (which I love), I am usually hanging out with my amazing son Ash, my gorgeous daughter Kitty and beautiful wife, Sarah. I love them to bits and value my time with them more than anything. We enjoy cycling, bush walking, canoeing or just hanging out with our dog in our native garden.

FPVM: Where do you live and is that where you grew up?

JUZ: I live and work in Warrandyte, Victoria, Australia. A very friendly town with a great community spirit. A place where many people visit to swim, canoe, fish, walk and picnic. My wife grew up in Warrandyte, but I was raised approximately 18km away in a suburb called Macleod.

View Larger Map

FPVM: When did you get into FPV?

JUZ: I got into FPV late 2010. I was intimidated by the technology, yet extemely excited by it. I spent a lot of time searching the internet, reading and researching. Finally biting the bullet and purchasing some goggles, camera, Vtx and Vrx.

Justin with his ground-station back pack

FPVM: Were you always only interested in multis or did you start someplace else?

JUZ: I started my RC experience flying helicopters. A blade 400 was my first real machine. I learnt to fly by following the lessons descibed on the web site called “Radd’s school of rotary flight” . Best thing I ever did. I learned to hover, then fly, without crashing once, well, until I started to try nose in. I moved on to a Trex 500, then Trex 700 nitro. Got my first quadcopter late 2010, it was a gaui 330x-s. I found quads to be so much more relaxing to fly and perfectly suited to FPV.

FPVM: What do you love about FPV?

JUZ: Flying. I have always been intriuged about all types of flight and I love the environment. FPV gives me the ability to enjoy and explore my surrounds in a unique way. I can interact with and explore the environment, zoom through trees, get close to the ‘roos, fly with the birds. It’s dynamic, exciting and just love the video and images that one can capture with FPV. The technology is cool and its fun to build stuff, fly it and then share my experience with the world. FPV has given me some awesome opportunities and experiences and has introduced me to many new friends the world over.

FPVM: Which other pilots do you admire and why?

JUZ: I have met many wonderful people because of my involvement in FPV and mulitrotors. I admire anyone who is looking to have fun and share their knowledge and experiences with others. I often hang out (and race) the Team Drop Bear pilots. They are a great bunch of generous, like minded guys who know how to laugh and have a great time. Also, Alex, Pete and Dave from Team White Llama, because they fly like me. They like to have fun and are always looking to push the envelope. They are also very nice guys who are extremely knowledgable and helpful to me and many others. One day I hope to fly with them. Luke Phillips (LSPPhoto) is another great pilot and very cool bloke. He knows how to make a cool FPV video too. Last but not least my mate in Arnhemland, Ant, who, like many people that I have met at OpenPilot, is very generous, genuine and gracious.

FPVM: As everyone wants to know, what FPV video TX/RX gear do you use?

JUZ: I use 1280mhz 300- 600mW Vtx with cloverleaf antennas on my machines. My ground station has two Lawmate Vrxs on eagletree diversity running a homemade crosshair and a skew planar antenna

FPVM: Which RC control system do you use?

JUZ: I flew on spektrum 2.4ghz for a long time. And never really had any issues with it. I don’t go on long range flights, so didn’t really need a LRS. However, a mate of mine in the States (Pete from TWL) entered me in a competition and I was lucky enough to win a Dragon Link UHF system. So, I use that now.

FPVM: Did you ever loose a multi?

JUZ: Never. I have had one experience where it took me one hour to find a downed machine. I always plan my flights and know my area. I don’t fly very far and try to always record the flight from my GS. I know my limits and operate within them.

FPVM: You’ve done some increadible flights. What’s on your “to do list” in terms of locations?

JUZ: Anywhere in Vietnam and/or Thailand. Uluru (Ayers Rock), Northern Territory, Australia. I am going to visit Arnhemland, Northern Territory, Australia later this year which will be an epic FPV trip for sure.

FPVM: Which 3 FPV videos (of yours) are your all time favorites?

JUZ: Its all about the emotions that flood back when watching my videos later on. Sometimes I have bad flights, sometimes good flights and every so often I have an amazing flight. I like to watch the flights that I enjoyed the most, the ones where everything just worked out right. I also like to capture and share the beauty of a place in my videos.

Number 1. Golden. Because of how I felt while flying. It was an amazing morning and a very fun flight. I like the music and the way the video came together.

2. Bali Happiness. Again, that morning was amazing the weather was brilliant, I was on holiday with my family which adds to how I feel when I watch the video. Its like looking at some holiday snaps

3. Dream. I love Wilsons Promintory and that beach is just incredible. Being there with just one other human was brilliant. Flying there was the best fun.

FPVM: Which 3 FPV videos (not yours) are your favorites?

JUZ: Thats a tough one…I don’t actually spend that much time watching FPV videos, I would rather be out doing it myself. Having said that, the video that got me into FPV and quadcopters was “Quadrocopter Extreme Jungle” by Chris Vogelzang. Brilliantly simple video and I was excited by the flying in a beautiful and remote location. Once I saw that video, I was like, I got to try that, it just looked like so much fun.

Another video that I was impressed by was “Hexacopter in Cameroon/Africa” by William Thielicke. Very well edited, some amazing locations and is easily one of my all time favourite FPV videos.

Lastly, I have to mention “Amazing Bells Beach Surfing Aerial Photography” by Extreme Aerials. The video is totally cool and features the beach which instantly insired me to fly down the coast. These guys have done some nice videos, and their music choice usually rocks.

FPVM: In your video “fpv, maybe” you forgot your aerial antenna. How difficult was it to get it from the car?

JUZ: Not very difficult at all. I had permission to drive almost to the top of the mountain. It was a steep walk from the car, but only about 500 metres (1km return). I had just run up there and didn’t really want to go back. Made for a good story though. LOL.

FPVM: What technical advancements in FPV are you looking forward to?

JUZ: Not much really, I am having so much fun with what I have now, I can’t imagine things getting much better. However, a cheap and reliable OSD and autopilot would be cool. The OpenPilot community is working hard to produce the worlds best autopilot (revolution) and maybe even an OSD (OP OSD) amounst other things. HD downlink? Now that would be cool. Better, more efficient batteries will be nice too. The future is bright and very exciting.

FPVM: Which multi rotor are you flying currently?

JUZ: Right now, I am flying two FPV quadcopters. The QAV500 powered by the OpenPilot revolution, MT4006 motors, xoar 10×6 props and plush 25A ESCs. And the QAV400 with OpenPilot CC3D, MT2212-13 motors, F30A simon k ESCs and 8×5 graupner props. I am very lucky to have the support of Tim at FPVmanuals, who has been very generous by supplying me with frames, motors and other gear. I am also a flight tester for the OpenPilot project which has allowed me to flight test their latest hardware, which is mega fun. The QAV500 is very fast and provides awesome, smooth HD video. The QAV500 has started a trend in FPV quadcopter frame design that has seen many variants appear since its release and with good reason. Its a fantastic FPV platform. The QAV400 is now my favorite all time FPV frame. Coupled with my current setup it is an absolute rocket that is capable of amazing aerobatics. Jello free 1080HD video, during high G, high speed manouevres is super cool.

Juz' QAV400 prototype

FPVM: You are active on the multi-rotor forums. What do you wish people would do/say differently out there?

JUZ: I mostly hang out at OpenPilot forums. The OpenPilot community is full of wonderful, helpful people and there is not much I would change. I do wish for people to respect one another and have fun. It should always be about having fun.

FPVM: Do you have any closing remarks?

JUZ: Big props go to the wonderful people at OpenPilot (especially David Ankers) for all the fun and cool stuff I get to enjoy. Thanks to everybody who creates and develops new technologies and frames that allow us to push FPV multirotor flight further. Thank-you to Tim (fpvmanuals) for his continued support, for his dedication to his customers and for producing great quality products. Spread the love, help one another, stay safe and have fun.

Present day photos taken by Scott James (Team Drop Bear)

EDITOR’S NOTE: Juz has recorded some incredible footage with his quads, here are my personal 3 favorites.

1. FPV Super Cool (QAV500)

2. FPV Bali Garden (HT-FPV)

3. FPV Summer Session (QAV400)

Links

Juz’s Website: http://juzfpv.com

OpenPilot Forum: http://forums.openpilot.org