I must admit rather than been a traditional "Instructables", this is more a personal obsession.
I hope the Instructables community will excuse my: "You live, you learn", that sounds like a title of a James Bond's movie. :-)
I've started this project 3 years ago (Ok, I have to say that I have also a full time job that keeps me extremely busy).
I've built 9 prototypes of the X-37B and I was able to fly the 4th version (using a V939 quadcopter) and the last one I made (which is a glider).
I've built so many prototypes that I came to the conclusion this unmanned drone, flies in a very mysterious way, because my models don't (at least keeping the same design).
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Step 1: Plans and Pizza Tray
Buy your favorite pizza at the local supermarket and you'll have a 3mm foam board included in the price.
Print my plans (adding 10%) and place the A4 on the polystyrene pizza tray.
Using (very carefully) an utility knife, cut the parts of the X-37ABC you live, you learn.
Using UHU Por (Foam Friendly), assemble all the parts.
Step 2: Electronics
Using the set up of my V.E.P. Very Easy Plane, you can control the X-37ABC using a Flysky FS-T6, a F939 pcb and a very small Lipo battery.
Step 3: Testing It...
I've successfully done a drop test (on a budget), inspired by the Yotuber Rctestflight.
My X-37ABC glides beautifully. You just need 10 metres of free-diviving to gain enough airspeed.