Step 1: What You Will Need
You will need:
• Some 1/4 inch plywood ( $0- I found some in the workshop)
• A lot of duct tape, but 2 rolls should do it ( You can find it at your hardware store for about 3-4 $ a roll)
• A breadboard (I got mine at radioshack)
• Hookup wire (22 gauge solid core from Radioshack)
• One RC servo ( any size but not too big)
• Two 55mm EDFs (Electronic Ducted Fans)
• Two 30A ESC (Electronic Speed Controller)
• Two 7.4v 1500mAh LiPo batteries
• RC car remote and receiver (2channels)
• Some small cardboard boxes ( I used the ones from the batteries)
• A place where you can cut wood. I used my CNC machine, but a bandsaw, a jigsaw and a drill will do the job.
• A reason to build the hovercraft (for Fun ) :)
• One arduino board ( can be any kind of arduino ).
• Vacuum tube
• Double sided tape
All the parts that I put links for add up to a total of $104, and since they are all from the same store you won’t pay much for shipping.
The rest of the parts will cost maximum $70 with the arduino, so you get to a total of $174 without shipping, but it will be worth it.
Step 2: Cutting the Frames
Trace the shape of the CD on the paper from side to side to make a round corner. Do the same for all four corners.
Step 3: Frame Continued
Now determine its center by folding it longitudinally and latitudinally. Do not fold it all the way to the edges, just enough to see the center. Mark the center with a pen.
Step 4: Frame Continued
Now take out the motor by unscrewing the two screws you revealed when you took out the fan.
Now you have the fan housing. We will use it to trace a circle in the middle of the paper.
Put the fan housing on the paper, with the center hole aligned with the dot that you made in the center of the paper.
Trace the outer edge of the duct on the paper.
Step 5: Frame...
Step 6: Still... the Frame
Step 7: Making the Skirt
Lay down several 30-35’’ strips of duct tape overlaying them 1/16 of an inch. Tape them down to the table at the edges so they won’t move. Now put facing down tape over them to cover the whole sticky surface. Fold over the sticky sides so you get a nice piece of fabric. This is the material for the skirt.Take the vacuum cleaner tube and put it over the ring-like frame. You will use the tubing as a guide to get the shape you want for the skirt. Use the fabric that you made to make the skirt. Use additional tape to hold it down. Be careful not to stick the tape to the tube. Now take the tape roll and go round and round over the fabric and the tube. Leave an open space so you can pull out the vacuum tubing.
After you pull out the vacuum tubing close the gap with tape.
It wasn’t that bad, was it?
Step 8: Putting Together the Two Frames
Step 9: Adding the Hardware
Now use a hot glue gun or the screws to tighten the servo in place.Glue the box in the back of the hovercraft as seen below:
Do the same with the other box but in the front. But do not cut a hole in the cover.
Step 10: Testing the Motors
Take an EDF, an ESC, and the radio system. Connect the wires of the Motor to the 3 thick wires of the ESC. Connect the ESC to the RC receiver and put batteries in the remote. Also connect the 7.4v battery to the motor when you are ready.Use the tutorial on HobbyPartz.com for the Remote to program it add do a test.
Speed up the motor and see if it blows backwards (towards the end with the motor). If not, switch any two of the thick blue wires. Squish the bullet connectors of the ESC with a pair of pliers so the wires do not slip out. Plug the servo in the receiver, reprogram it, and do a test with direction and propulsion.Connect the second ESC to the other motor and put in the place of the other one to check the flow direction and make it right just like the other one.
Take the Arduino, a 9V battery, and a battery clip.Connect the white wire of the ESC to pin 9 of the Arduino and the black wire to GND in the Arduino. Do not connect the red wire to the arduino.
Now complete the circuit with the potentiometer as it was a servo circuit, power the Arduino with the 9v battery and the motor with the 7.4v battery. Do a test: upload the servo code to the arduino, power the motor, and play with the pot until you figure out how to tune the motor. This may take some practice.
Step 11: Hardware, Continued
Now get a smaller and flatter box, I used a small Sparkfun box, and make a round hole for the propulsion EDF. Place the star servo cap on the bottom and glue it or use some wire to tighten it.
Step 12: Finally, the Final Step
If you want you can add protection gear as in the videos to protect the propulsion fan.
There you go, you’ve got your own homemade hovercraft. It’s great for a science project. You will certainly get an A wit this one. I did.
Watch the two videos for more in depth details about how it works and to see it running, well… floating.
Thanks for reading this 'till the end and I hope you liked it.