UberFly Super Honey Hawk Manual

UberFly Super Honey Hawk
Build Notes
© 2015 Jason Uberig / uberfly.ca
[email protected]
Document Date: 2015/12/09

Table of Contents
Contents
Table of Contents..............................................................................................................................................2
Preamble...........................................................................................................................................................4
Required Materials ............................................................................................................................................4
Tools / Supplies..........................................................................................................................................4
Finishing Parts............................................................................................................................................5
Build Steps........................................................................................................................................................7
Cut Out or Dislodge The Pieces.....................................................................................................................7
Chamfer the Control Surfaces........................................................................................................................7
Glue the Horizontal Parts together.................................................................................................................7
Attach the Ailerons and Elevator....................................................................................................................7
Glue in the Carbon Spars...............................................................................................................................8
Wing & Tail Spars.......................................................................................................................................8
Fuse Spar Joiner........................................................................................................................................8
Prepare and mount the Servos ......................................................................................................................8
Mount Aileron Quick Link Connectors.........................................................................................................8
Mount the Servos .......................................................................................................................................9
Glue the bottom fuse onto the Horizontal parts ............................................................................................10
Mount aileron and elevator servo linkages...................................................................................................10
Ailerons....................................................................................................................................................10
Elevator....................................................................................................................................................10
Glue the top fuse onto the Horizontal parts..................................................................................................11
Glue the rudder onto the fuse.......................................................................................................................11
Install the Tail Rotor.....................................................................................................................................11
Remove Tail Rotor Foam..........................................................................................................................11
Install Tail Rotor Motor Mount...................................................................................................................11
Install Fuse Joiners...................................................................................................................................12
Install Tail Rotor Carbon Supports............................................................................................................12
Mount Tail Motor ......................................................................................................................................13
Install tail bracing.........................................................................................................................................13
Mount rudder servo linkages........................................................................................................................14
Mount the nose motor..................................................................................................................................14
Mount electronics.........................................................................................................................................14
Glue on the Side Force Generators..............................................................................................................14
Optionally add landing gear..........................................................................................................................15
Post Build........................................................................................................................................................16
Center all Servo Channels and Controls ......................................................................................................16
Tail Rotor Subtrim / Centering......................................................................................................................16
Program Tail Rotor Mixing ...........................................................................................................................16
Control Throws / DR & Expo........................................................................................................................17

Mount Propellers..........................................................................................................................................17
Pre Flight Checks............................................................................................................................................18
Check Center of Gravity (CG) location......................................................................................................18
Control Directions.....................................................................................................................................18
Motor Direction.........................................................................................................................................18
Motor Direction –Tail Rotor......................................................................................................................18
Maiden Flight...................................................................................................................................................18
Pinwheels.................................................................................................................................................19
Epilogue..........................................................................................................................................................19

Preamble
The following document outlines the build process for the UberFly.ca Super Honey Hawk. It is not an
exhaustive instruction guide, but expects a certain level of proficiency on the part of the builder. If questions
arise during the build they can be emailed to [e-mail] and we’ll get back to you with answers -
assuming we have them.
Required Materials
The following are required to build the Super Honey Hawk. Please ensure you have these at hand
before beginning the build. Substitutions can be made where it makes sense and where your flavour of
electronics and/or hardware suits you. Alternates can be suggested if you like just let us know via email to
[e-mail].
Tools / Supplies
○Flat surface to build on - especially important when gluing carbon onto the flat surfaces... glue
them on a warped surface and get a warped plane!
○Very sharp X-Acto knife OR razor blades - dull blades just make a mess of foam.
○Glue:
The EPP that the Super Honey Hawk is made of has been tested with the following glues,
but others (such as wood or craft glue, etc.) could be used... simply test on some of the
scrap foam:
■Foam Tac glue by Beacon Adhesives for most foam-on-foam glueing
●Alternates:
○Bob Smith's "EPP Glue" is similarly flexible to Foam Tac
○Foam to Foam glue by deluxematerials.com
○Hot Glue (careful not to melt the EPP)
○Foam Safe CA (thin works best to get in the cracks between foam parts,
but medium can be made to work)
○Flexible CA / Gorilla Glue
■Regular thin CA for pushrod assembly
○Foam Safe “Kicker” or Activator (optional, but a great asset to have around to make things go
faster) when you use CA type glues.
○Needle nose pliers and/or small vice grips to build z-bends for the pushrods. Note: your kit may
have been provided with some pre-bent wires.
○Hot glue gun and a stick or two of glue for motor mount & landing gear.
○Pin-vise and a suitable set of tiny drill bits to drill out control horns and mount the motor on the
motor mount. Typical sizes needed: 1mm, 1.5mm, 2mm, 1/16”, 5/64”, 3/32”.
○Shrink tube for any wiring and electronics work as well as for attaching z-bends to carbon
pushrods. Typical sizes needed: 2mm, 4mm. Note: your kit may have been provided with
enough shrink tube.
○Soldering iron for wiring - depending on what electronics you choose and how they come from
your vendor.

Finishing Parts
The following are suggested parts. Equivalent components can be substituted with the understanding
that the goal is weight savings. "Light is MIGHT!" applies to these indoor planes.
○Main (nose) Motor:
For 2S operation:
1600 kv to 1800 kv
20 –25 grams
Suitable for 2S operation
For 3S operation:
1200 kv to 1600 kv
20 –25 grams
Suitable for 3S operation
○Tail Motor:
For 3S operation:
3100 kv
13 - 15 grams
Suitable for 3S operation
○Main (nose) Propeller:
Use what is appropriate for your motor. For the above kv's / cell counts:
■1480kv -> 2S or 3S use 8x4 GWS Electric
■1260kv -> 3S use 8x4 GWS Electric
■1660kv -> 2S or 3S use 8x4 GWS Electric (watch the throttle on 3S!)
○Tail Propeller:
Tail prop should be a 3D (bi-directional) prop. The one used on our prototype was one of
the Horizon Hobbies' / Blade 200 QX 3D props, part number: BLH7715. This prop is too
large a diameter for the 3100 kv motor so should be cut down to 4" diameter.
○Main (nose) ESC:
Suggested weight range for ESC is ~13 g and ~ 10 to 12 Amps such as.
○Tail ESC:
Suggested weight range: 6 to 9 g.
12 to 20 Amps.
Opto preferred / remove the red wire from the Rx connector!
MUST be bidirectional!
○Receiver:
Keep the receiver weight down. Remove the case (if it's not a gyro / stabilizing type) if
possible. The receivers used should be 3 to 8 grams max.
○Servos:
The plane needs 3 servos:
■Aileron: 9 gram
■Elevator/Rudder: 5 gram
○Flight Batteries:

The lighter the battery the better; however, ensure your battery can handle the minimum
current draw. The following have flown this plane well… with the smaller ones offering more
'floatiness', but less flight time vs. longer flight times, but less floatiness:
■2S ( 350 –450 mAh 25 to 30C)
■3S ( 350 –450 mAh 25 to 30C)
** Note: The Super Honey Hawk _can_fly off one nose battery; however, the best
performance is had with two separate batteries.
○Carbon:
■Wing Spar = 1) 27.5” x 0.236” x 0.04” (6 mm x 1 mm)
■Tail Spar = 1) 7.5” x 0.236” x 0.04” (6 mm x 1 mm)
■Ailerons = 2) 5” x 0.04” (1 mm)
■Elevator = 1) 15.25” x 0.04” (1 mm)
■Rudder = 1) 17.5” x 0.04” (1 mm)
■Landing gear = 2) 8.5” x 0.08” (2 mm)
■Landing skid = 1) 3” x 0.06” (1.5 mm)
■Tail Bracing = 2) 5” x 0.04” (1 mm) (*)
Note: only 2 braces needed on Super Honey Hawk
■Wing to Tail Joiner = 1) 14.75” x 0.236” x 0.04” (6 mm x 1 mm)
■Tail Rotor Bracing:
●Top = 2) 9.0625” x 0.06” (1.5 mm)
●Bottom = 2) 10.125” x 0.06” (1.5 mm)
■TR Motor Bracing:
●Top = 1) 3.2” x 0.06” & 1) 3.42” x 0.06”
●Bottom = 1) 4” x 0.06” & 1) 3.64” x 0.06”
○Wire
Note: Kits should contain the following.
■Z Bends: 4 (~ 0.8 to 1.0 mm diameter)
■Straight Wire: 4 (~ 1.5” long, ~ 0.8 to 1.0 mm diameter)
○Control Horns:
Control horns are provided in the kits; however, ¼" zip ties cut on an angle work great too!
Just make sure that the hole is directly above the hinge line.
○Pushrod Connectors:
■DuBro Mini E/Z Connector (p/n 915): 4.
○Landing Gear (optional):
The kit comes with two 2mm x 215mm (0.08" x ~8.5"). Those in combination with the wheel
kit are optional, but do help keep the EPP nice and straight when being stored.

Build Steps
Cut Out or Dislodge The Pieces
The factory kits may or may not require separation from the sheet they were cut from. If yours came
this way then carefully cut each piece out with a #11 X-Acto or similar sharp blade.
NOTE: Do not remove the tail 'sections' (ie. Tail prop cutouts) from the fuselage pieces. These will
aide with initiatl construction.
Chamfer the Control Surfaces
Cut bevels on the control surfaces and the fixed surfaces they will mate with. Once you start adding
the bevels / chamfers be sure to mark the top or left/right sides so that the bevels line up correctly later
when you glue the parts together.
Note: The BOTTOM surface of the parts is the one that has the slots cut in for the carbon flats / spars.
Glue the Horizontal Parts together
The horizontal parts fit together like a puzzle. They are keyed so there should be no issue getting it
together right. Use Beacon Foam-Tac or similar flexible glue to join the pieces. Ensure there is an
amble amount of glue on these interfaces to ensure a good, long-lasting bond.
Attach the Ailerons and Elevator
Using the Foam-Tac glue run a tiny, but consistent bead of glue down the length of one side of the
hinge point. Then bring the two parts together and then pull them apart! Wait a few seconds then put
them back together and allow them to set for a minute or two.
Ensure that you do this on a flat surface and that the entire hinge point/line is lined up as in the diagram
below.
Tip: If you lay down wax paper on your building surface you can do the hinging upside-down with the V
facing up. This way you'll be guaranteed to have a perfect alignment of the two sides of the hinge
point.
As to which side of the surface (top or bottom) should show the groove it depends on the control horns
you will use and what your tastes are. If the hinge point is on the top surface the paint scheme looks
nicer from the top, but if you have control horns that are too short to get the pivot over the hinge point
then sacrifice looks for even deflection and put the hinge point on the bottom for the surface. Here's a
diagram of what needs to happen in terms of control horn alignment:

Note: The bottom surface of the plane will be the one with the slots cut in for the wing and tail spars
(6mm x 1mm carbon flats).
Glue in the Carbon Spars
Wing & Tail Spars
Place the wing and tail on a flat surface and glue in (using Foam-Tac or similar flexible glue). Adhesion
will be best if you first take some scrap sandpaper and gently scuff the surface of the carbon strips
wiping the dust off with a damp paper towel afterwards.
Fuse Spar Joiner
Place the 1x6mm spar joiner carbon flat overlapping the wing and tail spars by ~ 1/4". Ensure this runs
at 4 to 5mm (~3/16") from the edge of the horizontal fuse on the tail motor mount side. It is critical that
this spar is attached directly to the wing and tail spars. This spar provides the main lateral rigidity to the
tail as well as a firm seat for the tail motor. Hot glue will work if you're in a hurry (be careful not to melt
the foam), but 5 minute epoxy on the ends where it meets the wing/tail spars would be a good idea.
Prepare and mount the Servos
Center the servos before performing the following steps and ensure the servo arms are physically
centred as well.
NOTE: Ensure you have the aileron arm centered properly as in the diagrams below BEFORE gluing it
into the foam. Otherwise you will have to cut the servo out to fix it or dig a hole down through the fuse
to reach the servo arm screw.
Mount Aileron Quick Link Connectors
The aileron quick link / EZ-Link connectors need to be mounted in an upside-down fashion so that
when the servo is mounted on the fuse the screw for tightening is facing downwards and is accessible.
See the following diagram for an idea of what this should look like:

Mount the Servos
This step can be left until later, but it is easier when you can lay the bottom horizontal fuse piece flat on
a surface.
Adjust the servo cut outs to suit your servo sizes. The rudder and elevator servos should stack
together laying horizontally with one arm on each side of the fuse. The aileron servo is installed with
the arm closest to the middle of the plane. Here's a couple diagrams to help.

Glue the bottom fuse onto the Horizontal parts
NOTE: Ensure that you have already chamfered / bevelled the top AND bottom fuse parts (ie. Vertical
stab where the rudder will later be mounted) BEFORE doing this step.
IMPORTANT: Do NOT apply any glue to the tail rotor section that will be removed.
Use the foam templates (A and D) to help align the bottom fuse to the horizontal parts. If you prefer,
you can also use a right angle to help. Glue the bottom fuse piece onto the upside-down horizontal
parts. You should see the wing spars while doing this part. Ensure that the nose of the bottom fuse is
lined up with the nose of the horizontal parts.
Mount aileron and elevator servo linkages
Center the servos before performing the following steps and ensure the servo arms are physically
centred as well.
Ailerons
The kit has pre-cut slots for the aileron horns. Simply glue the horns in so that the desired hole
(probably the closest one to the control surface) is dead center over the hinge line.
Next use shrink tube and attach a Z-bend and a straight wire to each carbon pushrod. The straight wire
goes into the EZ-Link and the Z-bend goes into the control horn on the ailerons.
Note: Use sand paper to scuff the Z-bends and straight rods before shrinking the shrink tube. Then
use regular thin or super thin CA glue to wick into both ends of the shrink tube.
Install the Z-bend in the control horn and then the straight rod into the EZ-link.
Elevator
Glue the control horn onto the pre-cut slot on the elevator.
Similar to the ailerons, use sandpaper to scuff two Z-bends.