Thrust Tube Former for TopRC Odyssey using Schuebeler 128mm HST EDF (or similar)

This former/mold/model is used to create a perfect tapered conical thrust tube for the 128mm HST Schuebeler EDF unit when using my other stl model for fitting the EDF called ‘TopRC EDF Conversion Adaptors for Schuebeler 128mm HST fan’ with the included Schuebeler adaptor ring that fits at the rear of the EDF to connect the EDF unit seamlessly to the thrust tube.

Print in whatever filament you like, I printed it using all kinds of leftovers on a 0.6mm nozzle, 3 walls, 3 bottom layers and 4 top layers using a 5 percent gyroid infill.  Keep the 4 top layers so that due to the low infill the final top layer is truly flat (see the grey top of the end section of the former where I only used 3 layers, that's why :).  This is needed for joining all the separate pieces with some glue to form the perfect geometric form to wrap either carbon fibre sheet or whatever you like, around the form to create the tube.

The tube is of course longer than required, when installed perfectly over the zero line of the EDF and glued in place you will have to cut off the part that extends out of the rear perpendicular to the zero line.  Be careful as to make 100 percent sure your tube is exiting on the zero line, otherwise ‘funny’ flight characteristics might occur :D

I used 0.25mm laminated carbon sheet for the weight, rolled up the sheet as tight as possible and then put the rolled up sheet wrapped in tape away for a month, that makes the sheet very curvy, and believe me, a lot less hassle to do the perfect wrapping around the former as it already is working like a spring clamping the former by itself eliminating ‘battles’ with the sheet, tape it tight to the tube leaving ample excess on the side side to work with later on to fit the adaptor ring, about one centimeter above the bottom of the wide side should be fine for a perfect snug fit. Use carbon cloth strip and long curing epoxy to join both halves using the TPU bands in another model published after this mold, more instructions follow there.

Glue all pieces perfectly centered to each other, one at a time, with a glob of UHU Por or similar glue, put on a heavy weight, wait until it has set in about a day, add the next piece like before, wait, repeat until all done.

The last piece called ‘Thrust Tube Former Adaptor Section’ is separate as I had to finetune to perfection the height of this last piece so that the Schuebeler Adaptor Ring for the EDF sits perfectly straight and at the perfect depth to connect to the EDF itself, helping a LOT with centering the tube in the plane when all is being brought together and assembled.

Max height of the pieces is 25cm, so I think it can suit any printer, I have a CR10v3, I could go higher but that would have been limiting for most users as they do not have the height this printer can attain.

Please note that the pictures of the tube in the plane are during fitting and adjusting, the blue tape might give the impression of non circularity or deformities, but all is straight, will post additional pictures of the final result later on when all is glued and cleaned up.

There will also be rings coming out as stl's to go around the tube for expansion prevention, I do not think with carbon sheet it will be necessary but nevertheless, better safe than sorry :)