Yes, I agree with all your points Brett,

It is all very subjective as to which size to choose to do.

I was specifically asked to do the 65 initially because some perceive this to be the best running version - whilst others would prefer the 75 because it was the latest and greatest of the lineage. I'm happy to do any of the displacements if the volume is there for cost effective production runs.

Some have requested I do it "while I'm still around" so they can buy spares for the future - rather than wait until they need them and I may no longer be around.

So if people for example want the 61 done because there are more out there in circulation/older/and getting closer to replacements I'm happy to oblige. It's all customer driven.

          And just to be clear, I think what you are offering is excellent, and I am sure if you did make them. everyone would get a top-quality result. So I am not at all trying to discourage you from trying.

      Brett

Yes, I agree with all your points Brett,

It is all very subjective as to which size to choose to do.

I was specifically asked to do the 65 initially because some perceive this to be the best running version - whilst others would prefer the 75 because it was the latest and greatest of the lineage. I'm happy to do any of the displacements if the volume is there for cost effective production runs.

Some have requested I do it "while I'm still around" so they can buy spares for the future - rather than wait until they need them and I may no longer be around.

So if people for example want the 61 done because there are more out there in circulation/older/and getting closer to replacements I'm happy to oblige. It's all customer driven.

Brian

Is there any reason the power wires to the esc could not just plug into an XT60 that is part of the pack like your balancing plug which is way cool!

Good idea. If you don’t have a separate arming plug and the battery is enclosed by a hatch, though, you would need to open the hatch to disarm the system. You could mount the arming connector on the battery and have a window on the side of the plane for the plug.

Another consideration is the ability to change an LRU in time for your next flight if you take an attempt.   I think this is Paul Walker’s requirement.  This causes extra connectors. Putting more stuff in the battery assembly might be a better way to meet this requirement.

PS - are there dimensions for those caps?  I need to design the mounts for the leads and the battery.

Do you have CAD?  If not, remind me of your postal address.

My latest Li-Ion 6-cell battery packs that I've made weigh 10.70 oz. These packs use the Molicel INR-18650-P30B 3000 mAh cells. These packs are 2.30 oz. lighter and have more capacity than the TP packs, which is substantial. These packs, so far, have worked extreme well.

    And, whatever the effect (weight or, more likely CG), it flies much better now!

     Brett

Measuring full travel can be deceptive if the bellcrank goes farther in one direction than the other.

   Exactly! Full travel means more-or-less nothing, as long as it is sufficient. What matters is the relative rate of each surface WRT the other (e.g. the flap moves 21 degrees down  and the elevator went 24 degrees up), and the absolute rate WRT the leadout movement (e.g. the flap went 21 degrees with 2" of leadout movement). You want to measure at a variety of up or down leadout movements and make sure the rate of movement is the same both ways, the rate of flap to elevator movement is the same both ways, and the flap to elevator ratio is what you expected

          Brett