Happy flyers Wipeout Instructions for use

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Construction manual

Rev. 0.93

17.07.2015

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Contents

1Summary.................................................................................................................................5

2Disclaimer................................................................................................................................5

3Specifications...........................................................................................................................6

3.1 Wing.................................................................................................................................6

3.1.1 Center of gravity (COG).............................................................................................7

3.1.2 Servo cut-outs ...........................................................................................................8

3.2 Battery plate .....................................................................................................................9

3.3 Motor mount .....................................................................................................................9

4Package content....................................................................................................................10

5Before we start.......................................................................................................................14

5.1 Foreword .......................................................................................................................14

5.2 Skill level.........................................................................................................................14

5.3 Required tools.................................................................................................................15

5.4 Required building materials.............................................................................................16

5.5 Electronics......................................................................................................................17

5.5.1 Choosing the right equipment..................................................................................17

5.5.2 Philosophies............................................................................................................17

5.5.3 ESC Settings...........................................................................................................22

5.5.4 Other electronics......................................................................................................22

5.5.5 Have everything ready!............................................................................................22

6Building tutorial......................................................................................................................23

6.1 Planning and drawing .....................................................................................................24

6.1.1 Planning your installation.........................................................................................25

6.1.2 Drawing borders ......................................................................................................27

6.1.3 Drawing CG at bottom .............................................................................................28

6.2 Preparation.....................................................................................................................29

6.2.1 Foam negative.........................................................................................................29

6.2.2 Kit parts...................................................................................................................31

6.2.3 Electronics...............................................................................................................46

6.2.4 Other stuff................................................................................................................50

6.3 Cut-outs..........................................................................................................................51

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6.3.1 Electronics...............................................................................................................51

6.3.2 Wires.......................................................................................................................57

6.3.3 GoPro mount (optional)............................................................................................59

6.4 Checking and testing ......................................................................................................61

6.4.1 Checking..................................................................................................................61

6.4.2 Testing.....................................................................................................................61

6.4.3 Removing ................................................................................................................61

6.5 Glue................................................................................................................................62

6.5.1 Wing stiffening.........................................................................................................62

6.5.2 Check straightness..................................................................................................65

6.5.3 Foam and motor mount............................................................................................67

6.5.4 Weighting and drying...............................................................................................79

6.5.5 Servos.....................................................................................................................80

6.5.6 Glueing in GoPro mount (optional)...........................................................................81

6.5.7 Remove surplus glue...............................................................................................82

6.6 Installation ......................................................................................................................83

6.7 Covering and sanding.....................................................................................................85

6.7.1 Covering servo cut-outs...........................................................................................85

6.7.2 Covering cut-outs (optional).....................................................................................87

6.7.3 Sanding (recommended) .........................................................................................91

6.8 Laminating......................................................................................................................93

6.8.1 Covering critical parts ..............................................................................................93

6.8.2 Spray glue ...............................................................................................................94

6.8.3 Laminating...............................................................................................................98

6.8.4 Cutting surplus foil.................................................................................................104

6.9 Assembling parts..........................................................................................................105

6.9.1 Winglets.................................................................................................................105

6.9.2 Elevons..................................................................................................................107

6.9.3 Motor and ESC......................................................................................................110

6.10 Determine CG...............................................................................................................111

6.10.1 Draw CG (if not done yet)......................................................................................111

6.10.2 Positioning battery bay...........................................................................................112

6.10.3 Cut-out...................................................................................................................113

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6.10.4 Gluing Battery plate...............................................................................................114

6.10.5 Taping borders (optional).......................................................................................115

6.11 Finalize.........................................................................................................................116

6.11.1 Taping critical parts................................................................................................116

6.11.2 Check straightness................................................................................................117

6.11.3 Testing electronics.................................................................................................117

6.12 Impressions..................................................................................................................118

7Settings and configuration....................................................................................................122

7.1 Rudder linkage..............................................................................................................122

7.1.1 Setting “Rookie” .....................................................................................................123

7.1.2 Setting “Common”..................................................................................................124

7.1.3 Setting “Wipeout”...................................................................................................125

7.2 RC Control....................................................................................................................127

7.3 ESC..............................................................................................................................129

7.3.1 Throttle..................................................................................................................129

8First flight.............................................................................................................................133

8.1 Preparations.................................................................................................................133

8.2 Launch..........................................................................................................................133

9Recommended Electronics..................................................................................................137

9.1 Motor (variety 1)............................................................................................................137

9.2 Motor (variety 2)............................................................................................................137

9.3 ESC..............................................................................................................................138

9.4 Servos ..........................................................................................................................138

9.5 Prop setup....................................................................................................................139

9.5.1 Propeller................................................................................................................139

9.5.2 Middle part.............................................................................................................139

9.5.3 Prop mount............................................................................................................140

9.5.4 Prop stopper..........................................................................................................140

9.6 Batteries (variety 1).......................................................................................................141

9.7 Batteries (variety 2).......................................................................................................141

10 Glossary ..............................................................................................................................142

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1 Summary

This construction manual contains next to its main function some advices, hints and much

knowledge which comes from many years of experience in RC and FPV engineering and piloting.

Don’t be afraid about the many pages of this document!

The meaning is to provide a maximum of information in this guide, which is also explained as

simple as possible. Inexperienced users for example can profit from the very detailed tutorial or tips

and tricks while some more advantaged ones can skip many steps of course and take out here

whatever they want.

We strongly recommend to follow the tutorial in any case (specially at the additional building

materials and important steps), as we are otherwise unable to guarantee you the flight experience

and specifications we provided in this guide and our videos (durability, flight times etc.).

Enjoy planning and building your Wipeout wing!

2 Disclaimer

This is a RC model kit which has many fields of application. In any case, always take care of the

security and privacy of other peoples. Don’t overestimate yourself! Fly safe and comply with the

rules which are applied in the country you fly.

We cannot be held accountable for any damages caused by or through any products sold or

endorsed through this website due to improper or even proper use.

If you are not following this construction manual exactly as explained and described, we

can also not be held accountable if your wing flys poorly or not at all!

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3 Specifications

3.1 Wing

Material

EPP

Wing span

912mm

Wing area

26.75 dm2

Wing profile thickness (middle)

40mm (at top cross-bracing)

Total up max weight

1.1 –1.3 Kg

Total up min weight

0.6 –0.8 Kg

Flight duration max (*)

~80 minutes

Flight duration average (*)

30 –45 minutes

Speed max (9x5 aeronaut fold prop) (*)

~110 km/h

Speed max (8x7 aeronaut fold prop) (*)

~140 km/h

Range max

Depends on used RC / FPV equipment

Altitude max

Same as above

(*) –With our recommended electronic package and building methods!

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3.1.1 Center of gravity (COG)

Measured from top

175mm

Measured from the back

143mm

COG Range

+ / - 2.5mm from this point (green dot)

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3.1.2 Servo cut-outs

Servo max width

32 mm

Servo max length

33.5 mm

Servo max height

16 mm

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3.2 Battery plate

Material

Plywood (extreme stable)

Thickness

3mm

3.3 Motor mount

Material

Plywood (extreme stable)

Thickness

4mm motor mount, 3mm side and bottom part

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4 Package content

1x EPP Foam in two parts with negative

1x Plywood motormound in four parts

2x EPP servohole covers

1x Plywood Battery plate, 1x Velcrostrap

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2x Rudder linkage in seven parts

2x Elevons balsa wood (pre-cut)

2x Rudder horn 2mm GFK

2x Winglets coroplast 4mm

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2x Wing stiffening 3mm (470, 500 and 230mm)

1x 2m laminating foil 80 micron

1x Cross-bracing 6/4mm, 8/6mm and 3mm

2x Oracover for Winglets 32x12mm

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1x Sticker „Wipeout – by Happy Flyers“

2x Sticker “Happy-Flyers.ch”

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5 Before we start

5.1 Foreword

There will be some very important points in this construction manual, which

are specially marked (the logo at the right) and some, which are less or

optional at all (marked with ”(optional)”).

The “Wipeout –by Happy Flyers” is an open platform, which will be usable for any kind of

environment. You can user your full FPV gear with GoPro, or you can go without any FPV

equipment at all and fly it classically. We haven’t made any pre-cuts for electronics (except Servos

of course) so it is completely up to you what to use and where to install it on the wing as long as

you pay attention to reach the centre of gravity (which can be very difficult on some setups)!

Since RC and FPV electronics brings many questions with it and these parts are one of the most

misunderstood things when planning and building a RC and FPV controlled aircraft, we took the

time to give some advices, examples and explanations about it.

Don’t rush things! Take your time and read carefully before you buy, choose, plan or build

something.

5.2 Skill level

Of course it is an advantage if you already have some experiences in building RC planes and have

some knowledge about the materials EPP, wood, fibre etc. and the necessary glues.

But don’t worry. Even if you are new to building foam RC planes, or building an RC aircraft at all,

we will guide you step by step through the building tutorial!

It is very important to read every single step carefully and follow our recommendations

because if you do not, it can result in major and probably uncorrectable problems like not

reaching the centre of gravity, which will mean your wing will fly poorly or not at all.

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5.3 Required tools

1. Cutter

2. Marker / Pen

3. Ruler (30 –50cm long)

4. Pointed pliers

5. Side cutter

6. Cross-head screwdriver

7. Laminating tool (100 –150°)

8. Something to spread the glue evenly / mixing glues

(like cable ties or brushes)

9. Weights (weight the foam during drying), just something heavy you can lay on the foam

The following tools are optional.

10. 2.0 mm Inbus / Allen key (for Scorpion Motor)

11. Solder station (if you don’t use a plug and play solution)

12. Scissors

13. Small screwdriver (stuffing rods and tubes into the foam)

10.

12.

13.

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5.4 Required building materials

1. 3M90 spray glue

(alternatives: 3M77, Tesa ultra strong)

2. Gorilla glue

3. Super glue (low viscosity)

4. Epoxy (two-component, 5- or 30 minutes)

5. Transparent tape

6. Painters tape (covering parts before spraying etc.)

The following building materials are optional.

7. Hot glue (for example for optional FPV camera)

8. UHU hard (“UHU hart”) or similar slow drying hard glue

9. Fibre tape

10. Super glue activator spray

10.

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5.5 Electronics

5.5.1 Choosing the right equipment

We can only say it once: Choose some equipment, which you thrust in or some people thrust in

which you know.

The secret is not only to choose separate components which individually work great, the secret is

to choose components which work great together!

Here you can follow our recommendations on our Shop site (for example our Products).

Don’t save money buying cheap parts from which your control to the plane depends (RC / FPV

equipment)!

5.5.2 Philosophies

Let’s think about all the important things, which can cause some serious problems, affecting your

range or causing some RF interference.

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5.5.2.1 Distance

A very important part when planning an RC / FPV system is distance between the single

components.

You can follow one simple rule here: Place RX and RF sensitive components (RC receiver, GPS

etc.) as far as possible from any transmitting component (vTX, Tracker etc.) or power part (ESC,

BEC etc.) as possible.

But keep in mind not to place these components too far at the back of the wing, since otherwise it

will be harder to reach the centre of gravity later!

So you see it is not that easy to find the right positions for these components. For your support,

there are some examples following later in this construction manual.

5.5.2.2 Wire length

Here we distinguish between two types of wires: Power wires

and Data / Signal wires.

About Power wires: Keep them as short as possible! The

wires coming from the batteries also count! See the picture at

the right for an example ESC / Current Sensor.

About Data / Signal wires: These wires for example are Servo, ESC signal, Video signal or OSD

wires etc.

Of course most of these cables will also provide power to each component. But the amount of

current will only be a fraction of the current compared on the main Power wires (ESC –Batteries).

Of course it is also better to keep these wires as short as possible in consideration of the previous

chapter. A very important part is the next chapter!

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5.5.2.3 Wire selection

Wire types for Data / Signal wires (RC receiver, OSD, GPS, vTX etc.) are one of the most

underestimated threads when planning a RC / FPV environment.

We strongly recommend using shielded or even shielded AND foiled cables for any of your Data /

Signal wires. Possible wires for example are Network cables (CAT 6 or higher), highly shielded

multimedia cables or USB cables.

Highly shielded multimedia Cable CAT 6 Network cable

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5.5.2.4 Crossing

When installing wires, especially Data and Signal wires, it is very important not to cross an

electronic part which generates some RF interference.

For Example:

Do not cross ESC or Current Sensor with a Servo wire

Do not cross any kind of BEC (specially the TBS Core / TBS PNP Pro) with any Servo,

ESC or similar Data / Signal wire (PWM / PPM)

Always keep some distance to electronics when installing wires. You can install all Data / Signal

wires at the bottom side of the wing for example (so we will do in the tutorial later) and the

electronics at the upper side of the wing. But also pay attention not to cross these electronics any

way.

These can cause some serious RF interference and reduce your range!

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