Fly-Sight v1 CAD model, outer shell transparent

Fly-Sight History: Part 1

Six months ago I was looking for a small, light weight camera to make another one of my smaller planes into a FPV platform.(First-Person Video)  While shopping I was pleasantly surprised at how the cost and weight of the airplane side components had dropped from when I first started dabbling in FPV.

It was now cheap to put together a system; however none of my friends were flying FPV.  What was stopping them?

I decided that if the cost of the system was low, then the remaining barriers to entry would be:

Not knowing it was cheap/possible

Not knowing how to put together a system.

I wanted to change that!

When I tell people about the Fly-Sight, my elevator speech is that it removes the ‘science-fair project’ part of assembling an FPV system, instead of choosing components piecemeal and assembling you can buy a proven set of components pre-assembled.

A circuit board mounted on an aluminum machining covered by a transparent piece of vacu-formed plastic, untrimmed.
The very first, just after vacuum forming the outer shell.  I couldn’t even wait to cut the excess plastic off before trying it out.

My first design used a lot of off the shelf electrical components, as I didn’t have much electrical knowledge at the time.  In hindsight I should have started by cracking the books first.

Tooling and parts for Fly-Sight V1. Aluminum soft jaws and machined aluminum parts.
Tooling and parts for V1

With the first few articles flying test flights, problems showed up quickly:

The first, was that the off the shelf battery charger/voltage controller board wasn’t able to meet its advertised current flow.  The first Fly-Sights would brown-out often.

After that was fixed, I was having problems with the wires soldered onto the transmitter breaking off their pads, the whole assembly was fragile until the shell was in place.  I ruined a few while making them.

Then the reed switch would weld itself together, causing the Fly-Sight to turn on once it was mounted, as desired, but failing to turn off.  I could pound the Fly-Sight on a table to shake the contacts apart, but, that would usually cause a pad on the transmitter to break off.

Clearly this would be no good to offer for sale.  (However if you want some of the excess parts, send me an e-mail and I’ll throw them in with your order.  The first orders will get the transmitters, which can be made to work with some soldering iron time.)

Bases for Fly-Sight v1
Piles of leftovers.

Despite all those failings the core of the idea was very good.  What stayed from this design was; mounting with double sided foam tape, having the Fly-Sight turn itself on only when mounted, having a dedicated on-board battery and charger, and general packaging of components.

V2 was designed to fix all those problems . . .