The gate is a 2.7 × 2.7 m solid blue panel with a 1.5 × 1.5 m flight hole and a 600 mm border. Five materials match the spec at different cost / mass / portability points. Pick by your priority — and mix approaches across multiple courses if it suits.
01 · Five materials side by side
All five produce a gate that matches the visual signature the detector saw in training (solid blue, 2.7 m outer, 1.5 m hole). They differ in cost, mass, portability, and build labor.
| Approach | Material | $ / gate | Total 18 gates | Mass | Pack size | Setup time |
|---|---|---|---|---|---|---|
| A · Plywood panel | 1/2" CDX plywood + 2×4 frame + paint | $78 | $1,400 | ~25 kg | flat sheet 2.7 m | ~5 min |
| B · Coroplast + PVC frame | 6 mm Coroplast + 1" PVC frame | $65 | $1,170 | ~6 kg | flat sheet 2.7 m | ~3 min |
| C · PVC frame + printed banner FLEX PICK | 2" PVC pipe + 13 oz vinyl banner | $95 | $1,710 | ~4 kg | 3 m tube bag | ~4 min |
| D · Sintra PVC sheet | 6 mm Sintra (blue, factory color) | $210 | $3,780 | ~10 kg | flat sheet 2.7 m | ~3 min |
| E · Blue tarp + PVC frame | 9×9 ft blue poly tarp + PVC frame | $48 | $860 | ~3.5 kg | 3 m tube bag | ~3 min |
02 · How they score
Best when the course lives in one place permanently. Heavy, stores flat in a barn. Survives weather for years with a proper paint job. Total $1,400.
Same shape as plywood but a quarter of the weight. The signboard you see on roadside real-estate signs. Cheaper than plywood when factoring in lower frame requirements. Total $1,170.
Best for multi-course. PVC pipe frame disassembles into 2.7 m sticks. Custom-printed 13 oz vinyl banner with grommets stretches across, hole pre-cut. Whole gate packs into a 3 m bag with the banner rolled inside. Total $1,710.
Closed-cell PVC foam board, available in factory blue (no paint needed). What pro signshops use. Looks closest to the sim render. 3× the budget. Total $3,780.
Stretch a 9×9 ft Home Depot blue poly tarp over a PVC frame, cut a 1.5 m hole in the middle, reinforce edges with gorilla tape and grommets. Looks rough, won't last a year, but you'll be flying for under $900. Good for "build one gate to test the concept" before committing to a real material. Total $860.
03 · Pick by priority
Approach E. Cheapest path to flying on a spec-shaped gate.
Approach A. Most durable. Heaviest. Set up once, never move.
Approach C. Whole 18-gate course fits in a Subaru.
Approach D. Factory-blue, paint-free, premium look.
Approach C. Pop pipe together, stretch banner, stake. Two people.
Approach E. One-person lift even with stand attached.
04 · Multi-course strategy
If you want to run the course on your 4-acre field today and a different 6-acre field next month, design for fast deploy. Three principles, all pointing at Approach C.
No piece longer than 2.7 m. PVC pipe friction-fit (no glue) so it pops apart in seconds. Banner rolls into a 3 m tube bag.
Banner gets damaged? Reprint at any local sign shop for ~$30. Frame survives. Faces are consumables.
Same A-frame stand fits all 18 gates. Sand-filled or staked depending on field. Bases pack flat under the pipe bundle.
05 · Approach C in detail
| Part | Spec | Qty |
|---|---|---|
| 2" PVC pipe | 2.70 m | 4 |
| 2" PVC 90° elbow | slip | 4 |
| Custom vinyl banner | 2.7×2.7 m, 13 oz, 1.5m hole, 8 grommets | 1 |
| A-frame stand legs | 1.5 m 2" PVC | 4 |
| Stand cross-brace | 1.2 m 2" PVC | 2 |
| Bungee cord (banner to frame) | 6" mini bungee | 8 |
| Tent stakes | 12" galvanized | 2 |
Build a single Approach E (tarp + PVC) gate for ~$50. Fly your stack against it. Confirm the detector likes the visual signature. Then commit to 17 more of whichever approach fits your real priorities — almost always Approach C for multi-course flexibility.