My DIY Ground (Base) Station project build for the DJI Mavic Pro and Inspire

Got some more work done on the ground station kit today.

First things first, getting those L-shaped brackets glued in place in both the lid, and in the base of the case too. @callum will be pleased to know I that I used Araldite in the end.

Masking tape holding them in place while I took the wife shopping this morning the epoxy resin sets.

Tape removed, all looking good.

You wouldn’t believe how many times I measured and re-measured the depth of these things.

Back from the shops :roll_eyes:

Time to crack on.

First step was to create the wooden panel that will sit in the lid, again using the cardboard template for reference and taking highly accurate measurements this time :+1:t2:

Drilling the corners out for the jigsaw blade to go through.

This is the recess I mentioned for the CrystalSky battery, as it protrudes quite some distance from the back of the display, and I want the CS sitting relatively flush in the lid here.

Glueing some wooden blocks on the back to hold the recessed pieces in place.

And now gluing the recess pieces in place.

This is so when it’s mounted in the case-lid, the whole thing will look solid, rather than just having a gaping hole in the middle :wink:

Like so:

This grommet is where the USB-C cable, and the twin antenna cables will exit the lid and head towards the bottom part of the case.

And a smaller grommet in the lower center where the USB-C cable exits the case and connects to the bottom of the CrystalSky.

So that’s the lid framing complete :clap:t2:

Time to start work on the bottom part next.

Here, we extend just beyond the center point, probably 60% or so. This is to allow enough room underneath to mount both the amplifiers, the battery, switches, wiring, etc.

By the way, these bloody rounded corners on the sides of case (and lid!) are a pain in the arse to work with :confused:

Not to mention the rounded bottom on the case too, this vertical panel took waaaayyyy longer than it needed to :face_with_symbols_over_mouth:

Glueing the two pieces of the lower box-section together, with some small blocks of ply for additional strength on the join.

Taking shape now :+1:t2:

Drilling the holes in the lower panel for the cable-exit (to the lid section), the main power switch and the charger connector.

And a larger hole on the vertical panel. This is where the main harness will exit, that goes off to the controllers.

This is a mockup of how the braided sleeve thing works.

It’s empty here, hence looking flat, but you’ll get the idea.

So there’s not much more to do in terms of woodwork now. I need to cut out a hole for the voltage meter, then sand the whole lot down, and that’ll probably be it for the panelling now :+1:t2:

9 Likes