Hi everyone,
I’m currently in the planning phase for my first custom ArduPilot multirotor build and wanted to get a sanity check before I start committing to the remaining hardware, assembly, soldering, and power distribution layout.
My goal is to build a reliable 850mm-class hexacopter for learning ArduPilot and custom UAV building, general photography/video, and eventually possible thermal/search use for my local volunteer fire department. I’m not trying to build a racing aircraft. I’m aiming for a stable, efficient, serviceable platform with good endurance and room to grow.
My target flight time goal is 45+ minutes if practical, but I understand that may depend heavily on final AUW, battery choice, hover current, and payload. I am planning to select the final endurance battery after the aircraft is built, weighed, and hover tested with real current data.
I’m aiming for a practical payload around 500g to 1kg, with a possible stretch goal around 1.5kg only if testing shows the aircraft has enough thrust, current, and thermal margin. I am not planning around a 2kg+ payload unless real-world testing proves the aircraft has enough margin.
Current planned build:
Frame:
X850 / ZD850-style hexacopter frame
850mm wheelbase
6-motor Hex X layout
Planning to run 16-inch props
Flight controller / avionics:
Holybro Pixhawk 6C
ArduCopter firmware installed
M10 GPS/compass
SiK 915 MHz telemetry radios
RadioMaster TX16S Mk3 transmitter
RadioMaster RP4TD ELRS receiver using CRSF over UART
PWM breakout board for ESC signal outputs
Power / monitoring:
Holybro PM08 DroneCAN power module ordered
I also have a PM02, but I decided it is probably too close to the edge for this size aircraft since it is only rated around 60A continuous
Planning a 6S battery system
Still deciding on final PDB/power harness layout
Propulsion:
6x SunnySky X4110S 400KV motors
6x Hobbywing XRotor 50A ESCs
16x6 folding props
Planning to use DShot if supported properly in the final ArduPilot/Pixhawk wiring setup
Battery:
Planning to start with a smaller 6S LiPo for initial hover testing and setup
Final endurance battery will be selected after I know actual AUW and hover current
Likely somewhere in the 6S 10000–16000mAh range later, but I’m not trying to choose that until I have real current data
Target flight time goal is 45+ minutes if the final weight and power system make that realistic
Payload goals:
Initial payload: GoPro/action camera or small FPV/camera system
Near-term practical payload goal: 500g to 1kg
Stretch payload goal: up to around 1.5kg if flight testing shows adequate thrust margin, motor temperatures, and hover current
I am not planning around a 2kg+ payload unless real-world testing shows the aircraft has enough margin
My intent is not to max out the aircraft. I’d rather keep useful payload in the 500g to 1kg range and preserve endurance, stability, and safety margin.
Current power distribution idea:
My current plan is:
Battery
to PM08
to high-current PDB or custom 6-way power harness
to six ESCs
I want the PM08 before the split so it measures total battery current.
I’m leaning toward a custom high-current harness rather than a small hobby-style PDB, but I would appreciate feedback on this. I would like the build to be serviceable, with ESCs replaceable without tearing apart the whole aircraft.
Main questions:
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Does this X850 + X4110S 400KV + 16x6 + 6S combination look reasonable for a stable endurance-focused hex?
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Is the Hobbywing XRotor 50A ESC a reasonable match for these motors and props?
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Are there any concerns with using DShot on this type of larger ArduPilot hex build, or would you recommend a different ESC signal protocol for reliability?
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For power distribution, would you recommend a custom harness, a specific high-current PDB, or something else for this size aircraft?
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Is the Holybro PM08 a reasonable power monitor for this build, or should I strongly consider a Mauch sensor instead?
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What wire gauge and connector sizes would you recommend for battery to PM08, PM08 to distribution, distribution to ESCs, and ESC-to-motor bullet connectors?
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Are there any obvious compatibility issues or weak points in this build before I start soldering and mounting hardware?
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Any ArduPilot-specific setup advice for a first large hex build? For example, parameters, safety checks, vibration concerns, logging, first hover test procedure, or mistakes to avoid.
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Does a practical payload target of 500g to 1kg, with a possible stretch goal around 1.5kg, seem reasonable for this frame/motor/prop combination?
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Is a 45+ minute flight-time goal realistic for this class of build if I keep the payload light and choose the final battery based on real hover-current data?
Things I’m intentionally not doing yet:
I am not buying the final large endurance battery yet.
I am not adding thermal payload yet.
I am not trying to add rangefinders, optical flow, RTK, ADS-B, or other advanced sensors before the aircraft flies reliably.
I am trying to keep the first version simple: reliable airframe, good power monitoring, clean wiring, stable hover, good logs, then expand later.
Background:
I have experience flying DJI-style drones and simulator time, but this is my first full custom ArduPilot multirotor. I originally started with a Tarot 690 frame, but after assembling it I decided it was too cramped and not ideal for what I wanted. The X850 seems like a better platform for clean wiring, larger props, and future expansion.
I’d appreciate any feedback, especially from people who have built similar 850mm-class hexes or used X4110/X4110S-class motors on 6S.
Thanks!