Zeller RES-Dart Instruction Manual

RES-Dart
Building instructions
Design & Prototype: Franz Heindler, CNC construction: Erich Penz
Construction instructions: Josef Bi inger
Distributed by
ZELLER Modellbau e.U.
Brunnenweg 11
4560 Kirchdorf / Kre s
AUSTRIA
Tel .: + 43 7582 21100 - 0, Fax: DW 99
office@zeller- odellbau.co
www.zeller- odellbau.co
This odel is not a toy and is not suitable for children under 14 years!
Version: 3.3
Created by: JB / FH / RZ
Created on: 01/29/2019
© by Zeller Modellbau e.U. - Reprinting, copying and forwarding are only per itted with express
consent!
NOTE: This version (3.3) has been translated fro Ger an to English using Google Translate with
no builder interpretation applied.
What you see is what Google provided!

Table of Contents
1 Model description …………………………………………………………………. 1
2 Technical data……………………………………………………………………… 2
3 Instructions ………………………………………………………………………... 3
3.1 Glider hull ………………………………………………………………….. 3
3.2 Electric hull ………………………………………………………………… 9
3.3 Wing ………………………………………………………………………... 11
3.3.1 Linkage of rudder flaps ……………………………………………… 25
3.3.2 Spoiler linkage ………………………………………………………. 28
3.4 Winglet with DSA tube …………………………………………………….. 31
3.5 Co pletion …………………………………………………………………. 36
Settings ……………………………………………………………………………… 38
4.1 Focus ……………………………………………………………………….. 38
4.2 Rudder deflections …………………………………………………………. 38
4.3 Fly in ……………………………………………………………………….. 39
4.4 Rubber rope high start ……………………………………………………… 39

1 Model description
My interest in flying wing aircraft was aroused any years ago. The MODEL book "Flying wing
sailors re ote controlled" by Reinhard H. Werner and so ething later showed the FMT specialist
book “Fascination Nurflügel” by Hans-Jürgen Unverferth Paths and wrong turns and helped e to
design flying wings that fly well. Much has developed since then, but just as uch had already
proven itself back then and has been incorporated into the Res-Dart construction. A rectangular
wing with a relatively large wing depth as with the CEOZWO, uch set as with the free-flight
arrows in the iddle of the 20th century. Century, sufficient sweep and rearwardly offset winglets,
as they were already Curt Weller in the 1980s with his Elfe 2, for ed the basis. Has been co pleted
the concept with a specially designed profile and through the use of DSA Marginal arches. I can do
it for anyone who wants to take a closer look at DSA pipes Ho epage www.zanonia-flyers.de by
Reinhard Siele ann and Dr. Hans-Jürgen Unverferth reco end. Research work was carried out
by the with great effort and also published (e.g. AUFWIND agazine 5/2016).
RES-Dart is a dart wing that co plies with the Ger an F3B-Res regulations and with Res
co petitions can be used. It was specially designed for this purpose designed and constructed. The
high starts should be done with a Res high start set under consideration of the typical rubber tension
and the class-specific one wind conditions. The profile used was specially designed. In the profile
construction value was placed on a very high axi u lift and good buildability. The thickness of
approx. 9.5% enables light spars and offers good torsional strength. Only in the area of the front
panelling, the profile contour is a curve. On the rest of the profile Si ilar to the AG35, flat
seg ents prevent the covering fro collapsing between the ribs. The chosen wing geo etry and set
were already practically checked and flown during the design phase. An i portant design goal were
good rubber rope high starts. The flight tests showed proble -free take-off behaviour and the
attainable starting altitudes proved to be very co petitive. The RES dart has due to its wing profile,
the low wing loading and the DSA winglets extre ely good-natured flight characteristics that
enable experienced RES pilots to get close crank out floor ther al syste s and so eti es even
close the ther al connection by hand find. Have fun building the RES-Dart and wish you all the
best for your first flight.
Franz Heindler
Page 1
2 Technical data
Span: 1,920
Take-off weight: Fro 500g in the glider or 580g in the electric version
Area: 47 d 2
Wing loading: 10.6 to 12.8 g / d 2
Winglet profile: flat plate
Arrow angle: 22 °
V shape: -1 ° / side
Control: Aileron, elevation, spoiler
Page 2

3 Assembly instructions
The structure of the odel is largely ade entirely of wood. For asse bling the
RES-Dart is necessarily experience and understanding of the construction of balsa
/ plywood constructions necessary. In addition, the individual co ponents are ade of very light
hand-selected balsa wood, which is partly quite fragile and a careful one treat ent requires.
The building instructions should be read and understood co pletely before building.
3.1 Glider hull
Only for the sailor version!
Side parts, base, cover and fra es - 3 poplar plywood (1 piece each)
( 2 x drawings)
Balsa 6 (1 pc.)
(1 x drawing)
The fuselage is designed as a classic box fuselage in plywood construction. He is tall
enough to run the receiver, receiver battery and possibly an altitude logger
acco odate. It is also provided with an adjustable high-start hook.
Danger!
The following individual construction steps refer to the hull in balsa
/ plywood construction.
The structure is analogous, the reinforce ents are o itted!
Page 3
1. Gluing the High start hook absorption in the fuselage floor. There ake sure that the 2
plywood part with the two s all ones drilling is used. Deviating fro series 2, the high start
hook ount directly in the botto of the fuselage should be illed (= 1 part fuselage floor
ade of Poplar plywood without separate high start hook ount out Birch plywood).
2. Shaft side parts and with 3 Birch plywood parts a plify. It is i portant to ensure that a left
and a right side wall built beco es! To better ones align ent of the parts should be the 4
beech rods (on the illustration by CFRP solid rod shown) into the 4 holes inserted, but not
glued! Additional reinforce ents can be now also on the side of the fuselage parts are glued on.
There are 3 distance fro the edges of the fuselage to be observed.
3. Hull botto with side panels stick together. It is i portant that the side walls right-angled to the
floor to be glued and the high start hook ount down shows so that a s ooth outside of the
fuselage floor. In this step will also be the three spacers between the
Page 4
glued side walls. The floor closes flush at the rear. Further ore care ust be taken that the the
botto of the trunk around the nose area about 3 ust be underlaid to to follow the contour
of the sidewall.

4. Head rib flush with side walls glue in.
5. Glue the back of the fuselage. In the bonding ust be ensured that the bags for the fuselage
cover pointing upwards, so that the lid attached later can be. The back of the trunk is in the
unglued condition very uch fragile. Optionally, between the front torsion pin and the trailing
edge of the large trunk opening a 10 strong piece balsa glued in will. With the grain across
to the hull elevated the the resilience of the trunk.
6. Glue the nose of the fuselage and the fuselage stick together. The nose with an integrated lead
cha ber is ade fro balsa and in layers constructed fro a piece of plywood.
Page 5
7. High start hook
The plastic coating the luster ter inal ust be re oved, so that we only have the etal part in
front of us lie to have. Next the 2 steel wire according to sketch bent will. (Sketch is not to
scale 1:1!) Attention, when very far back lying hook should be the angle reduced to 0 ° (=
parallel to Fuselage floor) as the odel otherwise to the early notching tends! Subsequently
will the Luster ter inal With the plywood ount as the steel wire with the washer ( etal or
GFK) as shown in the pictures see glued with 5 in epoxy. It is i portant to ensure that the
GRP and etal parts in front of the bonding sanded and be degreased.
Page 6
8. Gluing the high start hook in the trunk.
If the high-start hook ount is illed directly into the botto of the fuselage, the high-start
hook can be re oved executed and screwed.
9. The fuselage can now be sanded. The balsa trunk lid should be sanded at the sa e ti e.
Page 7
10. The trunk can now be covered. A paint job is not to reco end as opposed to it the fil
increases the strength. The two 4 beech rods (on the picture represented by 4 CFRP
solid rods) are only after the construction of the wings (will still needed there as an aid) in the
corresponding holes glued. When gluing on it ake sure that they are equally far on both sides
protrude.
Page 8

3.2 Electric hull
Only with the electric version and as an accessory!
Side parts - poplar plywood 3 (1 pc.)
(1 x drawing)
Fuselage floor and cover, fra es and reinforce ents - 3 poplar plywood (1 pc.)
(1 x drawing)
Fuselage cover and fra es - 3 poplar plywood (1 pc.)
(1 x drawing)
The electric hull, like the sailor hull, is constructed as a classic box hull.
The ost i portant notes:
o Engine ca ber and side pull are already considered. The fuselage floor and side part with
the additional hole in the front to be installed on the right so that analogously to the side
ove right results.
o Long triangular ledges at the botto , short ones above.
o At the latest before the final gluing of fuselage cover check whether the trial ounted
engine left back at the triangular oulding. ggf. building instructions
Page 9
o The fuselage lid consists of 2 divide. Before gluing the short back part the lid for insert the
battery opening so that an exactly equal gap results.
o The circular fra e without recesses serve as a te plate for conical grinding of the front
fuselage for spinner 38 dia
Page 10
3.3 Wing
(4 x drawings)
Page 11
(4 x drawings)
Page 12
The wing has a classic rib construction with partial balsa planking on the upper and underside. The
spar is ade entirely of wood. The spar straps consist of pine strips and are boxed upright with
balsa and for with it the nose panel has a closed profile that absorbs ost of the torsional forces
records.
The profile contour is only a curve in the area of the front paneling. On the rest of the prevent
profiles, si ilar to the AG35, flat seg ents cause the covering to collapse between the ribs.

Notes for wing construction:
o There ust be a left and a right wing half are built
o Ribs loudly before cutting out nu ber overview.
o The feet of the balsa ribs break off very easily and should therefore with great care treated
will. (Tip: the little feet can with thin superglue to be soaked in order to achieve a higher
strength. However, it ust be ensured that the superglue doesn't get up to rib soaked. This
would later ake re oval of the feet difficult.)
1. Put the slipway together and open fix it to the building board (pins, spray glue or thin double
sided use tape). The two slipway parts are on the separation point with two s all bevels
arked, these ust be on the be on the sa e side (see picture).
The illed lettering "FLUG" indicate the direction of flight. The associated arrows
de onstrate also on the illings of the front little feet the plywood root ribs. The s all illings
are for the ribs. It there are also larger illings, which later for the slipway ribs needed to build
the botto will.
Page 13
2. #13 rib shaft.
Carefully ove the two ribs put together and for control the profile course and the length the
use rib 12 (overlay). Then the two rib parts at the glue point on both sides thin superglue wet.
o Setting up the ribs. Before the positioning the ribs in the slipway these should be plastered. It
co es with rib # 1 on the root rib position began, then all other ribs in increasing order set up
and fixed.
3. The rib spacing fro # 16 to # 17 is about half of the other rib spacing. All ribs ust be
perpendicular to the building board to be fixed (pins, with a s all drop of glue fix).
Page 14
4. Base plate for spoiler and 3x3 Mandibular ridge between rib # 5 glue to # 8.
5. Lower spar chord jaw 6x3 stick together. The jaw ridge should be on two long edges are
cha fered to suck into the recess of the ribs to fit at the bonding ake sure that the ribs are
vertical and the rib spacing is aintained.
6. Upper spar strap jaw 6x3 stick together. The jaw ridge should be on two long edges are
cha fered to suck into the recess of the ribs to fit at the bonding ake sure that the ribs are
vertical and the rib spacing is aintained.
7. Attach the leading edge Balsa 6x6
Page 15
8. Prepare the upper cladding parts. So e parts need to be before the bonding are traded.
9. It co es with the front paneling began.

This should be done before gluing to the leading edge to be beveled (see picture) to the glue
gap low to hold.
Then the planking co pletely glued.
Page 16
10. Glue the rear paneling. In front the bond should be the two balsa strips can be attached.
Thereby beco es the right one rib spacing guaranteed. But do not glue the end strips yet!
Attention, the rear planking has at the top with 21 and at the botto with 22 a different
width!
Then the two planking parts between the front and rear paneling fitted and glued.
Page 17
11. Planking for aileron servo adjust and glue. This will on ribs # 12 and # 13 appropriate.
12. Glue the end strip. For the right one align ent of the balsa end strips are included in the balsa
te plate kit at. For greater stability you can carefully use the te plates beforehand low
viscosity superglue soaked will. It is also i portant to ensure that the right-angled cutting edge
of the both end strips pointing downwards (see i age).
13. Top side, except for planking at aileron servo, planked
14. The next step is the wing half fro building board taken.
Page 18
15. Setting up the slipway ribs for the achining the botto . The ribs are now in great shape
illings in the Helling base plate placed and in fixed at right angles to the building board.
There will be a rib in the area rib # 1, one in the area of rib # 9 and one in the area of rib # 17
set up. Subsequently beco es the wing half with the upper one planking down on the slipway
placed. The wing half is like on the i ages evident, with screws, halved toothpicks and the
4 beech rods fixed.
Slope Strips
(1 x drawing)
Page 19
16. Rudder fin glue in. The frontal plywood final rib with a distance of approx. 1 glue to rib
# 9.
17. GRP hooks for surface ounting glue into rib # 1. The GFK got to in front the bonding be
sanded and degreased. The illing edges ust be well deburred
18. Now the feet are off the ribs separated and possibly overhangs sanded flush with the contour.

Page 20
19. The spar boxes ade of 2 fit and glue the balsa. Between rib # 1 and # 6 is the spar boxed
on both sides, fro rib # 6 only one-sided on the trailing edge side. Danger! The waste that is
ade up the balsa board with the spar castings illed parts results, beco es later yet for the
round boxing required!
20. Opening for insertion into the spar casting drill. As drill beco es the alu inu insertion sleeve
used. To beco es one pipe end jagged. Then the pipe is through the illings in the ribs inserted
and the pipe in a drill cla ped. It ust care ust be taken that the pipe not bruised beco es.
Then it is done without uch pressure drilled through the caste syste . Link to video on
vi eo: https://vi eo.co /168662077
Page 21
21. The plug-in sleeve is fitted with a balsa piece on one side locked to prevent slipping to prevent
the insertion rod. There should be a little hole for it pressure equalization in the closure be
ade.
22. The plug-in sleeve is on both sides boxed upright with 2 balsa.
23. Now the tasting is flush with the Hol and ground to the profile contour.
24. Pull in the servo cable. On easy, cables adapted to the power require ent respect, think highly
of.
Page 22
25. Prepare the lower cladding. It have to deal with parts again will.
Page 23
26. Then the lower planking si ilar to the one above upset will. It co es with the front planking
started, then the rear glued and final the Inter ediate pieces fitted. During the drying ti e
should the wing half well on the sliding weighted or fastened so that there are no delays sneak
in.
27. After the bond has dried can the wing half of the taken slipway and sanded down. For the
leading edge contour balsa stencils are included. For greater stability, the use the te plates
carefully beforehand low viscosity superglue to be soaked.
28. Then the rudder flap split off. The rudder caste is fro the border of the 2 balsabrettes
created in which the illed parts for the spar casings found to have. The afford cut to length,
stick together and then sand down.
Page 24

29. The wings shell-ready and be sanded
3.3.1 Linkage of rudder flaps
General re ark:
The articulation of the two rudder flaps can be done in several ways. It is ake sure that a backlash-
free and resettable articulation is realized.
Below beco es exe plary a "Cross linkage" shown.
1. Production of the linkage ade of 0.8 steel wire and 1.2 CFRP solid rod The steel wire
will be like on the pictures shown cut to length and cranked (Z-bend) and then with the CFRP
solid rod glued with superglue. The cut the linkage beforehand and the shorten the CFRP rod if
necessary. Before the bonding have to all adhesive surfaces roughened and degreased will. The
bonding is done with shrink tubing secured.
Page 25
2. Breakthrough for linkage in the cut upper planking. Edge of the breakthrough with low
viscosity cure superglue (preferably fro inside to outside glue stains to avoid).
Page 26
3. Control horn ount.
To ensure a good introduction of force into the should ensure rudder flap the area around the
control horn be reinforced.
4. Control horn and servo are only starting glued after covering.
Note: When connecting, it ust care ust be taken that the linkage and place the control horn
in neutral for right angles. The sa e also applies to the rudder horn. This results in the sa e
rudder deflections up and down.
Both the elevator and spoiler servos the easiest way to tape (with asking tape wrap) or shrink,
if necessary grind, degrease and then with 5- in epoxy or heat seal adhesive on the fix the
planking on the inside.
Linkage variant exposed at the top
Page 27
3.3.2 Spoiler linkage
General re ark:
The spoiler flaps are opened by si ply pressing the flap open with the Servo ar . The closing is
ade by a piece of plywood guaranteed.