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Old 09-17-2019, 09:53 AM   #1 (permalink)
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Default 3D Printed Hard Case For R-XSR

The R-XSR is a nice full range receiver that is popular in quad builds. It's downfall for heli's is it's mechanical fragility - particularity its antennas and picoblade connector.

To address these issues, I put this case together and am now using it on two helis. Get the model files (for free) here.

https://www.thingiverse.com/thing:3863608

Features include:
- Mechanically secured 2.54mm "servo" connectors
- The option to use the inverted SBUS (from the board) or the one on the picoblade connector, depending on your flybarless needs.
- Status light visibility
- Access to bind button
- Ventilation for the voltage regulator and other circuits.

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To build, you'll need

- 2.54 mm double row right angle connectors
- A perf board to solder the connectors to
- 1.5 mm foam to hold the R-XSR in place without crushing it

Start with the bottom of the printed case

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Place the foam in the bottom of the case, and add the right angle connectors.

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Add the R-XSR and connect it to the pins. I chose Ground, VDD, (inverted) SBUS, and SPORT. Choose whatever suits your needs.

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Add some foam on the connector to secure it and keep it held together.

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Add the top and (carefully) use 2mm x 8mm bolts to secure the pieces together. Note the antenna are now nicely secured.

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Looking at the front, you can see that the connections will be secured.

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Last edited by Ferrite; 09-24-2019 at 09:13 AM..
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Old 09-17-2019, 10:19 AM   #2 (permalink)
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Very cool. Gonna sell it too?
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Old 09-17-2019, 10:37 AM   #3 (permalink)
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I have no plans to sell it, anyone can print it for free via the link above.

If someone doesn't have a 3D printer, there are usually "makerspaces" around. We have one at our local library. It's also possible to have it printed for you by an online service.
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Old 09-22-2019, 09:06 AM   #4 (permalink)
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Nice design. I wish FrSky had a receiver like this but with regular pin headers. The R-XSR is designed mostly for quads (hence the small connector and tiny wires, which are meant to be soldered directly to the flight controller) so wiring it to a heli is a bit cumbersome, especially if you want to use S.Port.

If anyone needs one printed, I have a printer and can do it. My sig has a link to my website.
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Old 09-22-2019, 09:12 AM   #5 (permalink)
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A bit of an inconsistency... your Thingiverse post has the screws listed as M2, but your HF post says M2.5. I'm assuming it's supposed to be M2?
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Old 09-24-2019, 09:14 AM   #6 (permalink)
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Quote:
Originally Posted by Number View Post
A bit of an inconsistency... your Thingiverse post has the screws listed as M2, but your HF post says M2.5. I'm assuming it's supposed to be M2?
Good catch. M2 8mm is the correct bolt. I updated the post above to correct the error.
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Old 09-24-2019, 12:12 PM   #7 (permalink)
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I'm planning to make the 3D-printed part in the next few days. Will let you know how it goes.

Currently I have two XSR receivers... Good excuse to upgrade to the smaller R-XSR.
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Old 09-24-2019, 12:29 PM   #8 (permalink)
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Nice! I've built a second one over the weekend for my Oxy 4. I really like how it cleaned up and secured the wiring. I'll post a pic later.

If you run into troubles, let me know!
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Old 09-24-2019, 01:02 PM   #9 (permalink)
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Is this the type of perf board you're talking about? I'd just cut it with a Dremel I guess.

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Old 09-24-2019, 02:24 PM   #10 (permalink)
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That will work if the holes have a 0.1" (2.54mm) pitch. They likely do.

You might want to solder on the long side so that you have some side area for the case to compress against. Here is the front view that hopefully shows what I mean:

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For cutting, a dremel would work, but I find it easy and effective to use a micro cutter like this one:

https://www.amazon.com/gp/product/B00FZPDG1K
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Old 09-24-2019, 02:37 PM   #11 (permalink)
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Makes sense. Much appreciated.
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Old 09-24-2019, 02:59 PM   #12 (permalink)
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they snap fairly easily but i mostly use a pair of diagonal cutters for small pieces of perf board like you'll need here.
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Old 09-24-2019, 06:16 PM   #13 (permalink)
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Some installation pics

Here I did the floss trick I use on my 3D planes. A little extra security against things coming unplugged.


Installation in my Oxy 4


Another one installed in my Fusion 270
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Old 09-25-2019, 05:57 PM   #14 (permalink)
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Default 3D Printed Hard Case For R-XSR

The college I work at has a MakerSpace. Free to use. Go figure.

The bottom piece printed more nicely than the top piece. It’s really the inside of the top that looks odd. Probably a feature of the particular printer I was using. Or maybe it’s normal; I don’t know anything about this stuff. Today I just learned what a raft is.

I’m also going to try to order a couple of them pre-made from our friend Number. Wouldn’t mind comparing how my MakerSpace does to something I know is good.

After printing them out and seeing your original pics, I understand more clearly how it all fits together. I like the design a lot. Very smart.

Everything else I need (receiver, foam, etc) is in the mail. Hopefully my next post will be the completed project.

Thanks for doing this.





Last edited by xoexoe; 09-25-2019 at 06:08 PM..
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Old 09-25-2019, 06:40 PM   #15 (permalink)
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When I printed, I used a 5mm brim and supports. The supports will really help for the top piece, with its overhangs.

This is what it looked like when printed:



This is what it looks like with the supports picked off



Thanks for the feedback on your progress. If I can make it easier for people to print or put together, I'd be happy to do so.
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Old 09-25-2019, 07:35 PM   #16 (permalink)
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Default 3D Printed Hard Case For R-XSR

Interesting. My top piece got printed upside down relative to yours. I used a MakerBot Replicator gen 5.

There were supports in places that I cleaned out before taking those pics... not enough apparently.

Doesn’t matter. Looks like it’ll work just fine.

Printing R-XSR protective case. (0 min 19 sec)
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Old 09-25-2019, 08:18 PM   #17 (permalink)
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You can flip and rotate the models in the software. I'm glad to it's going to work for you.
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Old 09-28-2019, 04:04 AM   #18 (permalink)
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Default 3D Printed Hard Case For R-XSR

All good!

The instructions you gave were perfect.

If I could give one bit of advice to others, make sure the wires from the pico connector are SHORT. Mine are too long and twist/bend a little when installed. The extra length (and some wicking that occurred during soldering) also forces the receiver a little too far back causing the antenna connectors to stick out a bit. I’m gonna live with it for now.... my antennae go directly into a diversity holder so it should be fine.

For me one row of connectors is G/+V/S-BUS and the other is G/+V/S.PORT. This unit is for a micro Spirit so I could just use the pico S-BUS pin directly and not hack-solder the board. (I won’t be so lucky for my Spirit Black.)

Haven’t installed it yet on my Oxy 2 because I need to rewire the heli first. It will be annoying to do so since everything was directly soldered so I need to cut wires and crimp on my own universal servo connectors. It will be well worth it though.

Great design. Thanks!

Here are my pics.





You can see on this next pic how the receiver is too far back because I suck at soldering and cutting wires.









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Last edited by xoexoe; 09-28-2019 at 08:36 AM..
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Old 09-28-2019, 11:06 AM   #19 (permalink)
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Thanks for the update and advice! I'm glad it worked out.
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Old 10-21-2019, 11:52 PM   #20 (permalink)
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awesome, i use the rxsr on most of my helis
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