MastWerks-BuddiHex Remote Mast Rotator v2

This is an update of the first version of the rotator system published earlier this year (model 64331).  This system uses more commercially available waterproof boxes and an updated controller circuit that has a smaller footprint and PCB.  A detailed Bill of Materials and Assembly Manual are downloadable using the links found below.  The firmware is available from the project's github site (link below).  

This project is a work in progress.  Please return regularly for updates which are listed at the end of this description.  

Printing parameters:

Filament:  Use a strong filament that will stand up to the elements.  We have used PETG for our builds.  

Layer height:  either 0.2 or 0.25 mm

Infill:  15-20%

Support:  Organic support works nicely to maintain openings in boxes and clamp parts

Firmware and software manual is available here:   lhbru/Mastwerks-BuddiHex-Rotator (github.com)

Update notices:

2024-08-27: the hex driver has been updated to improve fit.

2024-08-29: added gerber file for pcb in .zip archive.  

2024-08-29: the PCB for this project was posted on PCBWay at this link: MastWerks-BuddiHex Remote Mast Rotator Control Board v1.1 - Share Project - PCBWay 

2024-08-29: updated Bill of Materials to include source of PCB.

2024-08-31:  updated Bill of Materials to include screws, Anderson PowerPole connector and power connectors.

2024-08-31:  updated the Circuit Board Mount to allow placement in watertight box without the need to grind away two mounting posts inside the box.

2024-09-01:  posted an assembly manual for the system.

2024-10-06: posted new firmware that includes a web-based User Interface that allows operators to control the rotator using a platform-independent browser.  Users can now control the rotator without the need for the windows app.  We have simplified the process used to install the firmware into the microcontroller.  Builders can flash a binary file into the microcontroller using a web-based flashing tool.  The flashing process and setup procedures are described in the software manual available on the github link posted above. We have updated the Bill of Materials to include a buck converter that runs cooler than the L7805 voltage regulator thereby eliminating the need for a heatsink.   The assembly manual has been updated to include the optional use of the buck board voltage regulator.  

2025-09-15: Updated Bill of Materials with reliable source links for magnetometers.

2026-06-25:  Users of the rotator have reported that the hex driver loses its grip on the flat side of the motor shaft over time.  To address this problem, we have updated the hex driver to incorporate an M3 grub screw that tightens against the flat side of the motor drive shaft.  We also updated the ring collar to accommodate the increased diameter at the base of the modified hex driver. 

The new hex driver has a slot that allows placement of a thin square M3 nut.  These nuts are readily available from Amazon.  Once the square nut placed into the slot, an M3 grub screw, also available from Amazon, can be threaded into the nut and tightened gently against the flat side of the motor drive shaft.  It is helpful to place a small amount of blue lock-tite on the grub screw to prevent it from backing out over time.  Once the hex driver is fastened to the motor drive shaft, builders can then attach the ring collar to the plastic motor housing box.