Flight controller setups for hobbyists — a step-by-step build log.

Flight controller setups for hobbyists — a step-by-step build log.

This build log follows my recent quadcopter project where I evaluated ArduPilot and iNav flight stacks and focused on PID tuning, GPS rescue and sensor reliability for safe flying at a hobbyist level. I chose two flight controllers during the test phase, one running ArduPilot for advanced features and one running iNav for a simpler tuning experience, and I kept a detailed log on my blog at WatDaFeck.

Parts and board selection came first, and I opted for hardware that supports a wide sensor set to avoid compatibility headaches in the field. For ArduPilot I used a Pixhawk-style controller with an external compass and barometer, and for iNav a F4 board with an integrated IMU and a dedicated GPS module was sufficient. I also sourced good ESCs with telemetry, redundant power distribution and a small OSD-capable video transmitter to capture telemetry for later analysis.

The assembly was methodical and taught me the value of neat wiring and secure mounts for sensors to prevent vibration noise in the IMU. Step one was mechanical assembly and secure mounting of motors and props, which I completed before fitting the flight controllers. Step two was wiring power through an adequate regulator and connecting ESC signal and telemetry leads, followed by careful routing of GPS and compass cables away from power wires to reduce magnetic interference. Step three was making an initial bench connection to the ground station and confirming boot messages and sensor presence before attempting any motors spin tests.

Sensor calibration and GPS rescue setup were the next crucial phases, and I treated compass alignment and accelerometer calibration as non-negotiable checks before any flight. I placed the external GPS on a raised mast and tested for good satellites and proper fix quality, and I performed compass calibration with the completed airframe to capture any magnetic offsets. For GPS rescue I enabled the built-in failsafe and RTL features, setting conservative altitude and descent speeds in both ArduPilot and iNav, and I verified the rescue behaviour in simulation and controlled test flights to ensure the craft returned predictably in the event of signal loss.

PID tuning was handled in stages to avoid impulsive changes that could hide oscillations or make the copter unsafe. I began with default P and I values and then applied small increases in P while watching for high-frequency oscillation on hover, followed by gentle increments to D to tame any remaining chatter. When using ArduPilot I trialled the autotune feature on calm days and compared the resulting gains to those I developed manually with iNav, and I always recorded blackbox or telemetry logs at each tuning step to review gyro and error traces. I also adjusted filters and loop rates to match the platform characteristics, because sensible filtering often removes the need for overly aggressive D gains and improves flight behaviour.

Final flight testing concentrated on redundancy, telemetry, and logging to make sure settings behaved the same under real conditions as on the bench. I performed incremental tests from low hover to gentle manoeuvres while monitoring GPS lock, compass health and battery telemetry, and I used the OSD to keep critical info in view during flight. After a handful of flights I reviewed logs for any persistent biases, re-run accelerometer and compass calibrations if necessary, and set conservative GPS rescue thresholds and geofence limits to keep the aircraft safe during unexpected failures. The process gave me confidence that both ArduPilot and iNav could be tuned to a stable and rescue-ready state with careful attention to sensors and incremental PID changes.

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