Hyperflight X-res User manual

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Wingspan: 1999 mm
Length: 1220 mm
Profile: AG-Profile modified
Wing Area: 38.0 dm2
Flying weight: from 430 g
Wing loading: from about 11.3 g / dm2
Controls: rudder, elevator, spoiler
Dihedral: 12.0 °
CG: about 73 - 76mm

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The X-RES is a R(udder) E(levator) S(poiler) - high-performance model in predominantly wood construction
with 2m wingspan.
We have optimized the Allegro by Mark Drela using our ideas. It retained good flying characteristics
with practical wood construction.
The following points were emphasized in the design:
• Min sink
• Good high starting heights
• Easy handling, especially circling in thermals
• Consistent braking and steering effectiveness during landing.
The modified Mark Drela airfoil was optimized specifically for rib construction.
The airfoils, coupled with the aspect ratio of 11.6 and almost elliptical lift distribution, makes an
excellent soarer.
I have designed a model that allows long flight times, with the ability
to scan a large area for thermals. At the same time the X-RES, is a
model which the less experienced pilots can learn quickly.
I wish a lot of joy with the model
Alois Janowetz

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2. Building Instructions
General construction
We tried to keep the structure of the aircraft as easy as possible, without
compromising on the performance.
However, it is very important to proceed with the necessary care to build a
straight and high-performance model.
Some modular sheets are for sheeting. Please
cut carefully here so there it is sufficient material for everything.
Separate out the CNC milled parts only when required.
The inner corners radius on parts where the mill stops, have to be reworked
individually.
Bonds, unless otherwise described, thin Superglue, CA, should be used.
Epoxy 5 minute for fuselage / Wing screw connection joiner, Aluminum
tube CFRP link at the Wing.
It is explicitly stated in these instructions, if epoxy or glue should be
used.
If you are faced with unsolvable problems, you can reach me by email.

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Additional Resources / Tools
To build the following tools are required:
• Xacto knife
• Aluminum ruler
• Set Square
• Small handsaw
• Sanding blocks (80, 120, 180)
• Swiss Files
• Pins
• needle-nose pliers
• Cannula for superglue 0.9 mm are available from the pharmacy
• Superglue CA
• 5 – Minute epoxy
• White glue
• Flat Building board
• Sealing iron i.e Monocote Iron
What else is needed?
• Servos e.g. 2 x Dymond D60 1.6 to 2 kg and 2 x 0.5 kg D45 8mm
• Battery: four cells NmH AAA 800mAh
• Receiver: 4 channel as small as possible and reliable
• Covering film: about 2.5 m Oralight.

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2.2 Fuselage construction
2.2.1 Material for the fuselage
1. 3 mm plywood bulkheads for fuselage
1. 0.8 mm plywood reinforcements for sides and bottom of fuselage
1. 2 mm balsa fuselage, bottom and sides
1. 2 mm balsa side and bottom + small parts for the hatch cover
2. Bowden tubes (pushrod tubes)
1. 0.6 mm steel wire pushrod rudder
1. 0.8 mm steel wire pushrod elevator
1. 10 mm balsa fuselage nose pieces
1. 4 mm plywood surface mounting
2. 5 mm plywood adjustable tow hook
2.2.2 Fuselage Construction
First, the CNC milled parts are separated and the webs that hold the parts are trimmed and sanded
flush. Glue the two piece balsa sides of the fuselage and bottom together.
Now the 0.8 mm thick plywood reinforcements are glued to the 2mm balsa sides and bottom using
white glue. The top edges of the balsa and ply reinforcement are flush at the front of the fuse. The
fuselage bulkheads are used to align the reinforcing - not glued at this step.
NOTE:
Make a left and right fuselage side!

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Glue the fuse bulkheads with superglue. Make sure that these are perpendicular to the fuse sides.
Now two 4x4mm balsa longerons are glued in place on each fuselage side. Up to the wing saddle
(bulkhead 5) on top and to the nose on the bottom.
The two long bottom pieces must be scarfed together.
On forward fuselage, the lower piece is flush with the bottom of the 0.8 mm plywood reinforcement.
From the end of the plywood reinforcement, both the top and bottom 4x4 pieces are 2mm in from the
top and bottom edges of the sides. The top and bottom sheeting fits inside in this space later.
Assembled bulkheads and 4x4mm balsa longerons.
Use a spacer with 2 mm offset to locate the longerons.

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Taper the longerons at the rudder cutout so the back end of the fuse can be glued to the rudder.
Now the pushrod housings are sanded with rough sandpaper and run through the bulkheads, but not
glued.

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Next, the fuselage sides are glued together. Make sure they are parallel.
Before the frame is bonded at the end of the plywood reinforcement, insert the wing retainer.
Insert the 4 mm sheet of plywood with the 5 mm threaded hole toward the front of the fuselage.
Do not glue yet. That is glued later on, when the wing adjustment is made with the locking pin
Now the pushrod housings can be glued to the fuse bulkheads.
Ensure the housings are as straight as possible. It is recommended that the steel pushrods be inserted to
help straighten them. A slot still has to be cut into the side wall for the rudder pushrod housing.
Now the fuselage top is glued. The elevator pushrod goes through the elongated hole in the fuse top.

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Fuselage top with pushrod housing shown.
Glued fuselage bottom.
Finally, the adjustable tow hook and the balsa nose are glued with white glue.
To accommodate trim weight, the nose can be slightly hollowed.

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Wing retention system
(I built the wing first because of this step). If the wing locating dowel is not installed, drill a 5mm
(0.196 diameter or # 9 drill) hole in the leading edge and install the locating dowel at the center of the
wing.
Insert the wing into the fuse saddle, thread the nylon wing retention bolt into the plywood retainer
plate, and put the 3mm plywood wing locating piece on the dowel and in the fuse. Measure the wingtip
to back edge of fuselage and make sure the distance from each wingtip to the fuse end is the same.
Make adjustments to the hole in the plywood piece if necessary.
When wing is lined up, glue the ply wing locating piece in the fuselage. Remove the wing and
reinforce glue the wing retaining piece in the fuselage.
The wing retaining piece in the fuselage.

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Fuselage Sanding
The fuselage edges can be slightly rounded. The nose is first sanded to match the fuselage walls and
rounded thereafter. To the rear, the balsa of the sides can be sanded down. Sand the rear end of the
fuselage to match rudder thickness.
Elevator Installation
Install on the fuselage only after the wing center section is fitted to the fuselage.
The Elevator Pivot Assembly
First glue the two guide parts for the straight tube onto the elevator plate with superglue.
Then sand the nylon nut on all sides to roughen the surfaces. Apply a small amount of Vaseline to
nut and bolt threads so glue will not stick to them. Thread the bolt into the nut, through the
horizontal elevator plate.
Glue the control horn part onto the elevator plate and bolt using epoxy glue.
Sand the tube and insert through the holes, glue with epoxy.
Insert the 2 mm CF round pegs into the 2 mm holes in the elevator plate and glue with epoxy
about 4mm extending from the top side.

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The elevator pivot is located in front of the last bulkhead. Notch the fuse sides for the elevator
mounting side plates. Install the horizontal elevator plate onto the side plates using a piece of wire.
Glue the elevator mounting plates to the fuse sides, making sure the horizontal elevator plate is parallel
and level with the wing. Cut the pushrod housing to length.

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2.4 Construction Stage - Wing
The material for the sheeting of the wing should be cut in each phase of construction.
Some small pieces, however, are not shown here. Therefore, do not throw away the cut off
pieces.
2.4.2 Building Phase – Center Wing Section
2.4.2.1 Material Center Wing
1 sheet 5 mm Balsa root ribs A-1
1 sheet 1.5mm plywood A-reinforcing ribs A-2
1 sheet 3 mm plywood ribs and ribs for the wing joints
1 sheet 2.5mm balsa ribs
1 sheet 3.0mm balsa leading edge sanding templates
2 sheets 1.5mm balsa planking inside wing
1 sheet 2 mm balsa trailing edge inner wing
1 sheet 3mm balsa for spoilers
1 strip 3x3 mm balsa auxiliary web airbrakes
1 strip 4x10 mm balsa leading edge
2 6x2 mm spruce spar caps for center wing
2 carbon fiber rods 6 mm Ø, wing joiners
2 ALU tubes 58x7 mm joiner tubes
1 angle template 5 ° (plywood) alignment of the ribs A-9, B-1 for dihedral
2.4.2.2 Construction of the Center Wing
The printed plan must be glued together from the individual pages.
Tape he plans together using the alignment marks on each page.
Use a long ruler to check alignment of plans. Spar lines should be straight. See below.
First the 6x2 mm spruce spars are cut to length, slightly oversized.
Now a 1.5mm balsa sheet (bottom sheeting) is glued to the edge of the spruce spar.
Care must be taken to ensure that the parts are accurately aligned. The balsa can
now be cut off at the front, but it should extend about 5 mm in front of the ribs.
The balsa that is cut off should be saved for possible use in the future.

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Aligning the wing plan.
Cutting and gluing the 6x2 spar to the bottom sheeting.
The ribs are cut and sanded to fit on the spruce spar. The 3mm balsa spar webbing is also
prepared. The two ribs adjacent to the root rib have a section for the webs.
The outer ribs A8 and A9 are made of 3mm plywood.
An important criterion for distinguishing the ribs: All ribs of the inner wing are shorter as you
move to the wingtip.

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The two root ribs A1 from 5 mm Balsa and 1.5 mm plywood ribs A2 should be glued to each other.
Use epoxy. Glue in the 1.5mm plywood reinforcement at the wing mounting bolt position.
Place ribs on the plan and glue to spar. Do not glue ribs to bottom sheeting yet. Ribs A9 are glued at a
5 degree angle, using the 5 deg jig. See below. Make sure ribs are perpendicular to the spar. Use plenty
of glue around the spar and spar webs.

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Aligning end rib A9 with 5 ° angle jig.
Roughen and thoroughly clean aluminum wing joiner tubes. Slide aluminum tube into ribs A-9 and A-
8. Align at 90° to end rib. Gap between tube and spar webbing should be filled in with scrap 1.5mm
plywood. Coat ply filler, Al tube, and spar webs with epoxy and assemble. Picture shows top spar in
place, but do this step before top spar is glued in so the ply filler can be inserted.

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Glue in the top spar using plenty of glue. Carefully remove assembly from building board and turn
over. Fit and glue on the trailing edge balsa, flush with the top of the ribs, gluing from the bottom side.
The wing can be turned right side up and the trailing edge can be sanded to a taper on the top side,
starting from about 12 mm from the edge, so it is about 1mm thick at the trailing edge. Masking tape
can be used to protect the area that is not sanded.

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Thereafter, the middle part can be taken from the Plan and the bottom sheeting can be fully glued to the
ribs.

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Now a strip of 2 mm balsa is cut from scrap balsa sheet and glued to the front of the ribs. Take a long
sanding block to make the front edge straight.
After drying, cover the ribs to protect them and sand the 2mm strip to shape for sheeting.