Brushless Nailer

The Brushless Nailer is a variant of the Nailer but uses two or four 1503 brushless motors.

BOM List:

• 1 x TTGO ESP32 microcontroller with 1.14 Inch LCD Display and USB C port.

• 1 x 4in1 ESC 3-6S with BL_S firmware or similar.

• 1000 uF capacitor should be included with ESC. If not needs to handle up to 35V.

• 2 or 4 x 1503 Brushless motor with three mounting points.

• 2.0mm Banana bullet connector (6 pairs for single, 12 pairs for dual).

• 1 x Micro limit switch.

• 1 x 10kΩ resistor for pullup for trigger wiring.

• 1 x 7805 Fixed linear voltage regulator.

• 1 x XT60E Male Plug Connector.

• 1 x Spring for magazine release trigger

• 1 x 304 compression spring 9mm OD, 0.8mm wire size and 35mm long. Will need to be cut down to 30 or 25mm for best return pressure.

• Various M3 Hex screws.

• M2x8mm for motor mounting (6 for single, 12 for dual)

• 28AWG silicone wire for motor and microcontroller wiring.

• 18AWG silicone for XT60 to ESC connection

Arduino code:
Version: Arduino IDE 2.3.8.
Libraries: ESP32Servo, ESP32PWM, SPI, TFT_eSPI.

Assembly:

1. Start with the Handgrip which should have an included support. Remove support and clean up any roughness inside the rev trigger hole.

2. For each hand grip scale there will be an insert that should press fit into the exterior scale or be attached with contact glue.

3. Attach the right scale to the handgrip.

4. Attach the right mech cover only using the front screw hole. The rear screw hole needs to be left open.

5. Attach the magwell joint.

6. On the magwell add the mag release.

7. While attaching the magwell to the handgrip place the spring in-between both parts at the mag release location.

8. Attach motors with soldered male banana connectors to the middle cage printed.

9. Solder wires to the ESC motor pads and control pins on back of ESC. Mark each wire with the pads details for easier connection later. Tagging the connections once they are confirmed will also make it easy to do swaps or repairs.

10. Route control wires up handgrip to the top of the blaster.

11. Route motor wires to right mech cover and pass wires through the port to the outside of the blaster.

12. Solder switch with wires from C and NO pins. A pullup resistor and wire split will need to be added inline to allow for proper pins state detection for the switch. Refer to wiring diagram.

13. Mount switch to handgrip.

14. Attach XT60 port to rear pusher housing of choice. Wire from XT60 to ESC + and - pins for external power and attach rear housing to handgrip. Attach included capacitor for ESC.

15. Adding the L7805 below the XT connection and solder the voltage in from the XT60 to the VIN for the L7805. The ground and VOUT for the L7805 should be routed up towards the microcontroller area.

16. Route all wires behind switch and trigger spring backing.

17. Add trigger and trigger spring at correct length. Might require cutting for optimal compression.

18. Using a 1.75mm pin or length of filament add the 1:1 gear and pusher. Apply lubrication grease on gears and pusher to allow for a smooth action.

19. Attach trigger cover and left scale.

20. Attach left mech cover.

21. Make sure wires for microcontroller are all passed through the rear housing and top rail.

22. Wire up the microcontroller based on wiring diagram.

23. Connect the motor connections to the female banana connectors from the ESC.

24. Mount the middle cage to the magwell. Routing wires through side opening on magwell.

25. Attach the bottom cage piece.

26. Attach top cage piece.

27. Attach top mech cover.

28. Attach top rail.

29. Gently press microcontroller into top rail.

30. Add buttons to screen cover.

31. Flip over and attach to top rail.

32. Flash microcontroller.

33. Add power

34. Enjoy!

Please ask if you have any questions.