TantumBull

V2 is now live on Thingiverse. First post updated. Incorporates some suggestions from others as well as some of my own ideas. Ask questions, I didn't really do much documentation this time around. My nerf time got severely limited a couple months back and I'd rather push content than write exhaustive guides. But I'm here to help you get things up and running.

50% of stock nerf darts are whirly birds.  I have one Accustrike dart and that flies ok. 

From this I'm going to assume that when you say "stock nerf darts" you mean elites? Those are junk and the source of your whirlbirds. Accustrikes will be much better, as you've already noticed.

Also seems to be chewing up the darts.

 

Those workers are serrated, right? That happens with toothy wheels. Darts become an expendable resource. In the future, stick to smooth. You may lose some FPS with all other variables held constant, but it's worth it in terms of dart survivability.

I wonder if machined aluminium cages might help on the vibration front. I'd be curious to see if a Worker or Artifact cage would fit these wheels.

That's certainly possible. Might have different constrains on the minimum inner rim diameter but I'm sure that could be worked around.

Rev trigger. Or at least, a rev trigger. I've got mine wired up with the flywheels on one switch. Thinking about it, with how big that blower motor is, it's probably terrible for all parts involved, I should really try to set up separate wheel/blower triggers to stagger current flow a bit.

Yep, that's what I mean. The MOSFET powering the flywheels is controlled by the stock rev switch. MOSFET is rated to 195A so I'm not super worried about hooking up the blower to it: I use the same model to power on 4x wolverines in my 2 stage demo build. 

I am also thinking about giving it its own switch at the "foregrip", so I don't have to waste power on the FW motors when loading the coil. There are some functional advantages to having it on it's own circuit.

Went down a 10' coil segment, at Meaker's suggestion. I guess I was trying to run 20' before. Worked much better this time around. Starting playing with the servo gate a bit more and was able to control the fire. I was fluttering the trigger but you can see that this thing just really wants to spit out foam.

Interesting note: Pretty severe whirlybirding. It's possible that its hitting the inside of the stock orange muzzle, as I forgot to dremel it out like I normally do. However, I don't think that's all of it as AFAIK I'm the only person who is obsessive enough to do that to stock muzzles. I think the more likely culprit is the blower itself destabilizing the dart after losing contact with the wheels. Further evidence of this theory is the fact that the whirybirding increases as the tube empties, ie volumetric flow rate increases. It's an interesting problem to have, "muzzle blast" on a flywheeler. This might benefit from an extended Morpheus guide with venting. Or maybe some porting just before the cage.

Jerky camera at end is my mad rush to shut off the blower before my ears started bleeding. I really need to rig the blower to the flywheel mosfet circuit rather than just having an on-off slide switch.