Turning Dollar-Store Foam Into a High-Tech FPV Plane
With just a few basic components like a Seeed Studio XIAO ESP32S3, you can turn a $2 toy glider into a high-tech FPV airplane.
Radio-controlled (RC) airplanes may not cost as much as they used to, but they still aren’t cheap — at least not if you buy them from a hobby shop. However, if you are willing to put in the time to build your own, they can be surprisingly inexpensive. Hardware hacker Vishal Sharma took this to the extreme in his latest project in which he converted a $2 glider toy into a first-person view (FPV) RC airplane.
The project was built around a Seeed Studio XIAO ESP32S3 development board. This tiny board serves as the aircraft’s brain, handling everything from motor control to live video streaming. Paired with a miniature camera module, the system delivers a real-time FPV feed directly to a smartphone over Wi-Fi, eliminating the need for traditional RC transmitters and receivers.
To drive the propulsion system, Sharma designed a custom motor driver circuit. Rather than relying on off-the-shelf modules, he created a dedicated PCB populated with MOSFETs, diodes, resistors, and capacitors to efficiently handle current demands. The propulsion itself evolved during development, starting with small 720 motors and later upgrading to more powerful 8520 motors with larger propellers to generate sufficient thrust for sustained flight.
Mechanically, the build required significant customization to adapt the electronics to the lightweight foam glider. Sharma designed aerodynamic housings for the motors and a protective canopy for the camera and battery. These parts were resin-printed using a high-resolution printer, ensuring smooth surfaces that minimize drag — an important factor for such a small aircraft. Reinforcement came in the form of carbon fiber rods, while neodymium magnets enabled easy attachment of components. Despite all the added hardware, the final aircraft maintained a weight of under 90 grams.
Control is handled entirely through a smartphone interface. By connecting to the plane’s onboard Wi-Fi access point, the user gains access to a virtual joystick and live video feed. This streamlined approach reduces cost and complexity while making the system more accessible.
Flight testing revealed both successes and challenges. A key issue emerged when a 500mA-rated power switch limited motor performance, which Sharma resolved by bypassing it to allow full current flow. Additionally, the rear-mounted motor configuration introduced stability issues in windy conditions. Future iterations are expected to incorporate control surfaces like elevators, which are already supported by the PCB design.
For more tips on building your own inexpensive, DIY RC airplane, be sure to check out the video below.