The build and procedure notes are
The part listing is in the following table. Combo products are entries across different spreadsheets of this project, but split combo pricing to individual entries. Shipping discounts for multiple items from a vendor have been applied. No volume discounts.
The Horizon (Blade brand) components are priced the same on eBay and Amazon both with free shipping, as shown in the eBay and Amazon checkouts.
The entire craft is built without a machine shop and can be repaired by professionals in a car. Only light hand tools and light electric tools powered by car batteries are needed. This creates jobs.
Weight breakdown is https://nocomputerbutphone.blogspot.com/2018/08/iot-drone-weight-breakdown.html .
The World Is The Supply Chain Even For Specialty Parts - Cusped Airfoil
Cusped airfoil 10.5% thickness (joukowsky10.5 for short) rotor blades are interchangeable with conventional parts: The production build's cusped airfoil on the rotor blades is known to extend the efficient angle of attack range for thin blades, discussed in https://estebanhufstedler.com/2020/09/24/joukowski-airfoil-l-d/ and https://estebanhufstedler.com/2020/07/14/improving-the-naca-00xx-airfoil/. The Fusion 180mm blade is modified from the NACA0010.5 thin airfoil with a cusped trailing edge. The result is that its fuel economy is nearly identical to that of the NACA0012 medium-thickness airfoil under the same operating parameters (blade speed and alpha). The reduced drag for the high angle of attack also keeps the stall angle of attack outside the operating angle of 10 degrees, similar to NACA0012. One video of the endurance test (6 degrees collective pitch), 3 videos of performance tests (8 degrees), and 2 videos of an extraneous test (10 degrees) are below in order. The NACA0012 blades operate with optimal efficiency at 5 degrees of alpha in static tests, and due to the quirk of vertical rotor fluid dynamics, the optimal angle of attack for cruising is 1 degree higher than that of the static test. Since the cusped blades perform nearly identically to NACA0012 blades, the endurance cruising test was done with 5+1=6 degrees of collective pitch.
The World Is The Prototype Lab
The Align 300x has the same diameter and nominal length as those in the Blade Fusion 180. Align uses metric length 38 mm; Blade uses imperial length 1.5 inches. However, all suppliers use metric bolt threads and rod diameters.
1) Betaflight Software version 4.2.5 with the Zeus does not allow a reboot sequence to enter boot loader mode.
2) Not allowing entering boot loader mode means the hardware boot loader button needs to be used.
3) Using the hardware boot loader button means UART1 connecting to RF control receiver blocks USB flashing betaflight software version 4.5.2 unless UART1 is desoldered.
4) LED signal wire reassigned as S5 signal wire cannot flash FVT ESC, which needs resoldering to S4 pin to do the flashing.
Skystar Mini F4 solves all 5 hardware bugs.
The only difference between Skystars F7 and HGLRC F7's config is the pinout assignments and physical chip orientations.
$ diff dump_all_converged_IoT_HGLRCF722_6pin.txt dump_all_converged_
IoT_SKYSTARS_MINIF7.txt
6,7c6,7
< # Betaflight / STM32F7X2 (S7X2) 4.5.2 Mar 28 2025 / 21:47:17 (024f8e13d) MSP API: 1.46
< # config rev: 48588b7
---
> # Betaflight / STM32F7X2 (S7X2) 4.5.2 Aug 6 2025 / 03:55:33 (024f8e13d) MSP API: 1.46
> # config rev: 21f88d7
240,241c223,224
< serial 0 2 115200 115200 0 115200
< serial 1 64 115200 57600 0 115200
---
> serial 0 64 115200 57600 0 115200
> serial 1 0 115200 57600 0 115200
243,244c226,228
Skystars F7 Mini and SParkhobby 1303.5 2500kv motor verified here.
Every single part, bolt, and nut has more than one interchangeable source from independent business entities. See discussions in the following pages,
A summary of the dimensions of all component options is in the following table. And the reference component diagram is beneath the table.
The interchangeable Blade 180cfx rotor (1.69g hub + 2.24g grips +0.82g thrust +0.90g radial + 0.53g blades bolt + 0.25g dfc = 6.43g) weighs 0.45 gram less than production build (1.4g hub + 3.7g grips + 0.1g washers + 0.9g dfc +0.8g dfc bolt = 6.9g). The grips are nearly identical (4.48 grams) in weight to production build when blade and DFC boltings are included; the DFC links are 0.4 grams lighter when the radial swasharms are included as part of DFC links.
This interchangeable Blade 180cfx rotor has thrust bearings and has zero slop of the feathering shaft, as is, without flanged washers. When you look up the rotor dimensions chart, you see a 0.25 mm hub-grip gap, but this gap is filled by the rubber grommet fully.
The installation is more complex with thrust bearings than the production build without thrust bearings. Production can not use the thrust bearings unless an assembly line is trained for it. The Blade Fusion 180 rotor has been verified in the substitution note, but Blade 180cfx rotor has not been verified.
