Hyperflight sky series User manual

HyperFlgiht Sky Series Assembly Guide
HyperFlight Ltd
Drybank Farm
Fosse Way
Ettington
Stratford-on-Avon
Warwickshire K CV37 7PD
www.HyperFlight.co.uk
[email protected]
© 2011 HyperFlight
Revision 1.0
Sky Series Assembly Guide 1.odt
HyperFlight Sky Series Assembly Guide 1

Warning, this is not a toy!
I you are new to the hobby o lying RC model airplanes, DO NOT attempt to ly this
model by yoursel ! There are hundreds o BMFA (British Model Flying Association)
clubs in the UK. Ask your local hobby shop or the location o the nearest club in your
area, or check out the www.bm a.org.uk (or your national modelling organisations)
web site. Many clubs o ten have quali ied instructors to teach you how to ly. I you
are an accomplished pilot then you should have no problem in lying this model.
However the Supra-e can ly very ast, and is potentially a lethal object. Do ly
responsibly, and make sure your third party liability (eg BMFA) insurance is valid.
Limit of Liability
All HyperFlight Models products are constructed to the highest standard and made
strong enough or reasonable usage by an experienced and responsible r/c aircra t
pilot. By keeping this model you con irm that the parts have not been structurally
damaged and are it or purpose as received.
The cra tsmanship, attention to detail, and actions o the builder/ lyer o this model
airplane kit will ultimately determine the airworthiness, light per ormance, and the
sa ety o the inished model. You con irm that you take ull responsibility or the sa e
usage, construction, and maintenance o the model, and you will not hold
HyperFlight Ltd or its owners, sta , agents, contractors, or helpers in any way
responsible or any damages or injury that may occur as a result o operating or
lying this model. HyperFlight’s sole obligation shall be to replace those parts o the
kit proven to be de ective or missing. I you are not willing to agree to this binding
condition o sale please return the model in as-received condition to Hyper light or a
re und.
Acknowledgement
HyperFlight would like to thank Steve Bowdler or his help writing this guide, based
on his build o a Sky Master glider.
We would really appreciate input by other builders – both instructions or speci ic
models, and some construction photos.
HyperFlight Sky Series Assembly Guide 2

Preparation
The mouldings are o reasonable quality but may need cleaning up in a couple o
places. The uselage had a ridge around the centre line where the two halves had
been joined. Not signi icant but I gently removed it with a ine ile anyway.
The wings had “ lashing” along the leading edge rom the moulding process which, I
believe, is more signi icant. I removed this with a ine ile also.
I could see that as the uselage has been constructed or toughness rather than
minimum weight it will be necessary to mount all the equipment as ar orwards as
possible to obtain the required centre o gravity position.
I decided to build the model in the ollowing order – Wings, V tail then uselage. This
would allow me to check the CoG at various stages and ine tune the uselage
installation as I went along.
Wings
For wing servos I decide to use Hitec 5065s as already had three. In the past I have
attached them by wrapping masking tape around the servo and epoxying them
directly to the wing upper sur ace. However, I have ound that the servo occasionally
wriggles loose in the tape so I tried a new ( or me) technique with this model.
I bought some CNC cut plywood mounting plates which are designed or the 5065
and are close it around the servo. These are epoxied to the wing upper sur ace and
the servo is pushed into the mount and secured with a couple o spots o hot melt
adhesive. They made setting up the controls much easier as the servo can be
removed as o ten as needed be ore being inally glued in place.
The 5065s are 12mm thick and they only just it into the aileron bay with literally no
thickness to spare. This is the maximum thickness or the servo and assumes no
addition thickness due to mounting the servo in the wing. There is more thickness
available in the lap bays.
1. Servo mounts
a. Remove about 1mm rom the servo mount width so that it is a snug it
between the wing ribs and slides up against the rear o the main spar.
The servos are all itted with the horn acing a way rom the uselage.
b. Wrap the servo with a single layer o cling ilm to prevent the servo
being bonded to the mount or wing.
c. Place the mount on a lat sur ace and press the servo home until the
servo and mount are lush on the underside.
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d. Coat the underside and contact edges o the mount with adhesive. I
used microballoon / epoxy mix or this as it provides some gap illing
whilst remaining low in density.
e. Press the servo and its mount into the servo bay and make sure that it
is pressed against the wing upper sur ace.
. Clean o any adhesive which is squeezed out.
g. Once the adhesive has cured pull the servo rom the mount and
remove the cling ilm.
2. Servo wiring
a. Use thin multi strand wire or the wings
b. Thread three lengths rom the aileron servo bay to the root
c. Cut o the servo connector and solder directly to the wiring. One or
positive, one or negative and one or control signal.
d. Use heat shrink to insulate the solder joints
e. Run a single length o wire rom the lap servo bay to the wing root
. Pull the aileron servo positive and negative cables out into the lap
servo bay.
g. Cut o the lap servo connector
h. Solder the servo positive to the positive cable, servo negative to the
negative cable and the servo signal to the new wire in the lap bay.
i. At the wing root solder on a 4 way socket e.g. Deans micro, and
insulate the solder connections with heat shrink. Connect the cables in
the ollowing order- positive, aileron signal, negative, lap signal.
j. Make up two leads to connect the wing wiring to the receiver.
HyperFlight Sky Series Assembly Guide 4

k. For each lead use two servo extension leads.
l. Cut o the servo end connectors o each lead.
m. On one lead remove the positive and negative cables completely
n. Solder a matching our way plug to the cut ends o extension leads to
match the connections to the wing – positive, aileron signal, negative,
lap signal.
3. Fitting the control sur ace horns
a. Open up the pre-drilled holes in the control sur ace horns to suit the
linkages to be itted as this is easier to do be ore the horns are ixed
into the wing.
b. Replace the servos in their mounts with the servo arms itted.
c. Put a piece o masking tape on to the control sur ace in the
approximate location o the each control horn
d. Using a straight edge mark the masking tape where the horns are to be
itted.
e. Cut a small slot in to the control sur ace or each horn. Be sure not cut
completely through to the upper sur ace. I used a disc in a Dremel or
this.
. Lightly abrade the control horns in the area where they will be bonded
to the wing.
g. Give the bonding sur aces o both wing and horns a light coat o
adhesive. I used micro ibre / epoxy mix to ensure a good bond with
excellent gap illing properties.
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h. Place each horn into its slot and align with the servo and ensure it is
vertical. Each pair o horns (aileron: aileron, lap: lap) should be as
identical as possible in terms o the position o the linkage holes. They
should be the same height above the control sur ace and the same
distance rom the hinge line. Ailerons should have the hole directly
above the hinge line. Flap horns can be placed with the hole a little way
behind the hinge line to assist in achieving the large downwards travel
o the lap.
i. Leave the adhesive to cure.
4. Fitting the linkages
a. Cut eight lengths o 1mm diameter piano wire.
b. Form Z bends in the end o our o them and L bends in the other our
c. Cut our lengths o 3mm od x 1mm id carbon ibre tune
d. Centre the wing servos and the clamp the control sur aces in the
neutral position.
e. Fit Z bend push rods into the control sur ace horns
. Slide the CF tubes over them
g. Fit the L bend push rods into the servo horns.
h. Slide the CF tube over the L bend rods and centre equally on both the
L bend and Z bend rods.
i. Run a small drop o thin CA adhesive onto each rod / CF tube joint and
allow to cure.
j. With the servos and control sur aces still centred, add a small drop o
thick CA adhesive to each push rod to horn joint. Zap with a small
amount o accelerator and the lex each joint. This removes all slop in
the linkage.
HyperFlight Sky Series Assembly Guide 6

V Tail
The V tail angle mounting in the uselage boom is 110 degree so the V tail needs to
be ixed at this angle. T he V tail is designed to be removable but I could not ind a
secure and yet removable linkage system to use between the control horns and push
rods so I decided to make my V tail ixed.
1. Joining the V tail halves.
a. Stick a length o parcel tape or similar
to the building board at right angles to
the ront edge o the board. This is to
stop the V tail being bonded to the
board.
b. Mark a centre line on the tape
perpendicular to the straight ront edge
o the building board. This is the centre
line o the V tail join.
c. Find or make two suitable pieces to
prop up the V tail at the correct angle.
They need to be exactly the same
height and about 100mm high. Two
pieces o scrap balsa block will do.
d. Calculate the distance the props need to be way rom the centre line to
achieve an inclusive angle o 110 degrees. With 100mm props this is
142mm each side o the centre line. Mark two more lines perpendicular
to the board edge at this distance each side o the centre line. This is
the position o the inside edge o each props.
e. Hold each prop in place with its inside edge on these lines.
. Dry it the V tail halves in place with the join over the centre line and
the V tail panels propped up at the correct angle by the props. Align the
hinge line o the rudder sur aces over the ront edge o the building
board. The hinge line should be straight rom one end o the V tail to
the other.
g. Once everything its, remove the V tail halves and coat both sur aces o
the join with adhesive. I used micro ibres / epoxy mix or this as there
was some gap illing to be done.
h. Put the two halves back into the jig and push the two halves together at
the join. Align the hinge lines over the board ront edge and the join on
HyperFlight Sky Series Assembly Guide 7

the centre line. Check that everything is square and true. Leave the
adhesive to cure.
i. Clean up the upper sur ace o the epoxy join and dry it the supplied
centre piece to the V tail join. Adjust as required to get a close it o the
centre piece to the V tail.
j. Epoxy in place ensuring that the holes align with those in the V tail
2. V tail push rods
a. Fix the control horns as required. I removed the horns rom their
mounting bases and epoxied them directly into slots in the control
b. Make the push rods rom two 1 metre lengths o 0.9mm diameter piano
wire.
c. Form L bends on the ends o each
d. Slide the push rod into the actory itted outer and it the L bend into the
control horn.
Fuselage
Mount all the RC equipment well orward in the uselage in order to achieve the
correct CoG without adding any lead.
1. V Tail servos
a) Trim the ply servo tray to it the chosen servos
b) Fix the servo tray in position by using epoxy to bond it to the uselage
sides
c) Make sure the tray is itted such that the servo horns are at the same
height as the pre-installed push rod outers.
d) My servos are itted in the area o 130mm to 155mm measured back rom
the uselage nose.
e) Make up two short push rods long enough to reach the V tail push rods
and overlap by 20mm. Make L bends in the end o each
) Centre the servo horns and the V tail sur ace.
g) Fit the short push rods into the servo horns.
HyperFlight Sky Series Assembly Guide 8

h) Slide a short length o heat shrink over the V tail push rods.
i) Apply a small amount o epoxy to the V tail push rods, align the servo push
rod with the V tail push rod and slide the heat shrink over them both.
j) Check the sur ace and the servo are still centred and then shrink the heat
shrink with a hot air gun or similar. Allow the epoxy to cure ully.
k) Treat the ends o the push rods with CA adhesive, as per the wings
l) Make tapered support pieces rom 3mm balsa to hold the ront ends o the
push rods in place and eliminate play in the V tail controls. Fix the
supports between the uselage sides and the push rod outers with CA
adhesive.
2. Final assembly
a. Fix the receiver behind the servo tray with Velcro
b. Run the wing extension leads rom the receiver to the wing seat. And
connect to the wings.
c. Fit the wings to the uselage with the nylon screws.
d. Connect the V tail servos to the appropriate receiver channels.
e. Fit a receiver battery pack into the nose o the uselage with Velcro.
. Hinge the canopy with Diamond tape along one side and ix it shut with
a smaller piece o tape on the other side.
g. Program the radio as required.
3. Set up
a. Rudder unction - +/- 12mm travel at root o V tail
b. Elevator unction - +/- 6mm travel at root o V tail
c. Aileron unction - +12mm, -8mm
d. Flap unction - 80 degrees down at ull lap
e. Centre o Gravity - usually 70mm rom wing leading edge - see
HyperFlight web site
HyperFlight Sky Series Assembly Guide 9