Aluminum: Optimum Build Material

James purchased several lengths and styles of aluminum, including tubing, flat bar and half moon.
The expected weight of the aluminum (based off density calculations) was lighter, the tubing proving itself as an optimal choice. It has the capability and availability to route the necessary wiring through the arm itself, while producing less drag.

Next step is to fabricate the bearing housing, arm rotor base plate and motor assembly.
It should be noted that aluminum will be used for all abovementioned parts, as it is light, and in the case of the motor assembly, is a good heat conductor.

The heat that the motor generates is significant enough to require a cooling fan for extended usage. The reason for this is that it was initially designed as a remote control helicopter motor, where the blades of the helicopter would actively cool the motor itself. An aluminum housing will allow contact between the motor and the housing, dispersing the heat of the motor into the housing, allowing it to cool more effectively. I also plan to use a thermal grease to further lubricate the process.