After some fun with the FPV plane I recently built, I was looking for the next step. I decided my next project would be to outfit it with an Ardupilot. I have looked at the Ardupilot before, and just did some more extensive research, and here is what I have come up with. I would also like some advice on what I should buy too.

My plane is an Easystar by the way.

The Ardupilot itself
Shield extension kit with airspeed
FMA XY sensors
Not sure what GPS yet
Programming cable

Now I have a lot of questions.

What is the purpose of the Z sensor, and is it required for the latest Ardupilot? How imperative is it to have?

I will continue my post in about an hour, I am at a friends house, and my dad just came to get me...

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The Z sensor is to calibrate the XY thermopiles. It is not required but simplifies the field setup process a lot.
Ok, now for the rest of my post.

Ok, I see that the Z sensor is not required. I might get one later, but my budget limits me. I currently have $250 to spend, plus another $100 if needed, but would like to keep it not too much over $250.

I see that the recommended GPS is a 4hz model that costs around $110 if I am correct. I would like to know if there is another GPS around 4 or 5hz that costs around $60 or lower that is known to work. If I have to, I will probably go with the 1hz, but I would much prefer higher refresh rate.
You could probably find one (such as here), but you'd have to handle the wiring harness and 3.3v power supply yourself. Unless you're an expert at electronics, you'll have trouble getting it to work.
I do plan on getting an xbee setup for telemetry, but I am worried about the range considering its only 60mw. I wish there was a way to transmit data via the audio channel much like the EagleTree OSD, that way its dependent on my much higher power video TX, with less complication, but I assume thats not possible.

What are typical ranges for it from people that have used it?
Xbee will take you as far as you can legally fly (visual line of sight). 900Mhz is at least 1 mile, and often 2. You really don't need any more than that.
One other question. When wiring the FMA copilot, does the FMA connect directly to the board for the Ardupilot, or do I just normally wire it up to the servos?

Does this specific sensor work for Ardupilot?

http://www.fmadirect.com/detail.htm?item=1778&section=20

I thought I read something about the old sensor being analog and the new one digital, making them non compatible?

I noticed that the 3.3v reg is on the Shield itself. Does this mean that I powering one of the GPSs you linked me would be possible with that? Why would the wiring be hard, assuming the connection is the same?
Thanks for the help BTW.
Scott, we don't use the FMA CoPilot, just the sensor. You use an XY sensor from the old CoPilot, but not the CoPilot II.

We can't help you with wiring a GPS that we don't support. I really don't know how to make those work, since I've never tried. You should be able to use the 3.3v reg on the Shield, but you'd have to figure out the wiring harness yourself. Warning: you might have to program the GPS module for the correct baud rate, and that can be tricky, too, since each one is different.

I understand you're trying to save money, so you might be happier getting the EM406, which we support right out of the box. It's just 1Hz but works fine (you may not notice the difference)
I might just go with that. This gets more expensive every time I look, lol.
Well, we list everything you need on one page right in the tabs at the top of the site, with a total of around $270. So the costs should be no surprise. BTW, this is the cheapest autopilot in the world, so if it's too much for you this might not be the right hobby for you ;-)
Yes, I realize that. Please don't think I am complaining, I just spent more money than I would have imagined on my FPV plane, and this is not that much compared. Just trying to save every dollar worth saving. In the end its all worth it for such a great hobby.

Here is what I have out so far, tell me what you think as a final setup.

Ardupilot board (Sparkfun)
EM-406A (Sparkfun)
FTDI basic breakout for USB, 3.3 or 5v? (Sparkfun)
Shield v2 kit (Diydrones)
FMA Thermopile sensor, although considering full XYZ from Diydrones

Female to female servo wires
Pins for Ardupilot
Extended GPS cable

Missing anything? What else would you recommend that might be useful?

Can you explain why having the Z sensor makes setup easier? Do you know of one that can be purchased separately instead of getting the more expensive XYZ from DIY?
I'd go with the DIYDrones FTDI cable instead. It's bulletproof.

If you don't have a Z, you have to go through a process at the field where you point each window of the XY at the sky in turn. It's pretty fiddly, but if you want to save some money that's one place. I'm afraid we don't sell the Z by itself and we don't recommend mixing and matching them with other mfg's sensors.
Put simply the Z sensor removes the need to calibrate your setup before flight. It also gives your system one more reference for which way up is.

With high gain antennas 2.4 low power xbees are capable of 4km, but in some ways its very like pointing a torch at a fly keeping the beam antenna pointing at the UAS.

Perhaps just keep adding each bit slowly, stupid to try and spare a buck and that one buck could have saved the entire system from some silly accident. Its frustrating I know.

Sell the FPV gear ;-)

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