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The Extra 300 KIT K-55 Manual

Contents

1. 1 RADIO GUIDANCE SYSTEM 4 CHANNEL MINIMUM REQUIRED ENGINE 2 CYCLE 60 90 4 CYCLE 90 1 20 PROPELLER TO MATCH ENGINE SIZE 3 DIAMETER SPINNER LARGE ENOUGH FOR PROP TO FIT WITHOUT MODIFICATION FUEL TANK TO MATCH ENGINE 12 OZ SHOWN ON PLAN 24 SILICONE FUEL LINE 3 DIAMETER WHEELS 1 1 4 DIAMETER TAILWHEEL 2 OZ BOTTLE MEDIUM CYANOACRYLATE GLUE CYANOACRYLATE ACCELERATOR 20 MINUTE EPOXY LIGHTWEIGHT BALSA FILLER 1 2x 8 x 12 FOAM PADDING ROLLS OF COVERING FUEL PROOF PAINT FOR COWL AND WHEELPANTS OPTIONAL ITEMS SCALE PILOT PITTS STYLE MUFFLER SMOKE SYSTEM COMMERCIAL INCIDENCE GAUGE NECESSARY TOOLS AND SUPPLIES MISCELLANEOUS RUBBER BANDS WAXED PAPER MODELING KNIFE AND RAZOR BLADES SANDPAPER ASSORTED GRITS INCLUDING COARSE 80 MEDIUM 150 AND FINE 220 320 SANDING BLOCK T PINS at least 75 BUILDING BOARD 24 x60 ELECTRIC DRILL 1 16 DRILL BIT 3 32 DRILL BIT 5 16 DRILL BIT 3 8 DRILL BIT ALLEN WRENCH SET SMALL SCREWDRIVER MASKING TAPE LONG NOSE PLIERS COVERING IRON AND HEAT GUN RAZOR SAW SPRAY BOTTLE SMALL SOLDERING IRON amp
2. Place waxed paper over the elevator section of the plan Trim and glue the 5 16 square balsa sticks over the plan pinning as you go Glue the HORN MOUNT ASSEMBLIES and the CORNER GUSSETS into the frame GUSSET HORN MOUNT ASSEMBLY RN li 9 GUSSET 7 VERTICAL FIN CONSTRUCTION 4 Steps Collect the items needed to construct the VERTICAL FIN They include 3 16 x 5 16 x16 BALSA STICKS PT 4369 1 16 x3 x 18 BALSA SHEETS PT 4538 Cover the fin portion of the plan with waxed paper Trim the 3 16 x 5 16 balsa sticks and pin over the plan gluing as you go Place the 1 16 balsa sheeting flush with the Leading Edge L E and mark the width of the sheet onto the frame Apply Jet to the frame up to the width marks and permanently install the sheeting Pin down to insure a flat assembly Trim the sheeting and use the drop off to cover the remaining area of the fin side trimming to the profile of the fin as you go Flip the fin over and repeat the sheeting operation as illustrated THIS COMPLETES THE VERTICAL FIN CONSTRUCTION PUT IT ASIDE UNTIL YOU ARE READY TO INSTALL THE HINGES RUDDER CONSTRUCTION 4 Steps Collect all of the parts you will need to construct the RUDDER They include 5 16 sq x 16 BALSA STICKS 4370 D C BALSA SHT 5517 PT 43331 CONTAINING 1 3 16 HORN MOUNT D C BALSA SHT 5520 PT 3332 C
3. Make a small opening in the firewall Attach the fuel lines and feed them through the opening in the firewall 3 Slide the tank platform forward and insert the tabs into the notches in the firewall Glue the wide end of the platform to the notches in Former B GLUE HERE BOTH SIDES RUDDER CABLES A word here about rudder actuation The EXTRA uses a pull pull system The rudder servo must be located as shown on the plans to insure the correct cable alignment with the cable exits This is not a problem if the die cut servo tray D C SHEET 5519 supplied in this kit is used Solder the threaded coupler to the cables being careful to keep both assembly lengths equal With the servo in the neutral position trim tab centered attach the cables to the control horn and to the servo arm Adjust the snap links until the rudder is perfectly straight A ball bearing servo is recommended for the rudder control Je y 2K 5519 3482 Es ELEVATOR PUSHROD GUIDE You will note that the plans show an elevator support guide glued to the top of Former D This two part support is on D C SHEET 5519 and is to be installed after the servo is connected to the elevator horns After you finish covering the entire model permanently install the hinges The GENERAL INFORMATION BOOK also covers this CONNECTED TO d CONNECTED TO THE ELEVATORS 40 CONTROL SURFACE TRAVELS Use the
4. 30 GROOVE OUT 20 21 22 Use the wing to locate the doubler disc Correctly position the disc to Former and epoxy in place To the wing mounting block insert a 6 32 blind nut into each hole on the surface Mere the holes are centered Make sure that the nut spurs are full set into the wood Tap with a hammer to insure a good fit With the blind nuts on the under side test fit and trim if necessary the block assembly into the cutouts in the doublers When you have a proper fit Epoxy in place Install the gusset into the slot in the slant former and down into the notches in the doublers The gusset should also rest on the wing mounting block When you are satisfied with the fit glue in place SLIDE INTO SLOT For the next few steps you will need the wing Place the fuselage on a stable flat surface Insert the wing pin dowel into the hole in Former B Slide the wing as far forward as it will go 4 True the wing to the fuselage by adjusting the distance from the wing tip to the tail until both sides are equal When you are satisfied secure the wing to the fuselage with tape 31 23 24 25 26 Flip the wing fuse over and drill a small pilot hole no larger than 7 64 through the wing Remove the wing from the fuse and drill a 5 32 hole using the pilot hole as a guide
5. The Extra 300 KIT K 55 Wingspan 68 Length 61 Weight 7 5 8 5 lbs Engine Size 2 cycle 60 90 4 cycle 90 1 20 INSTRUCTIONS If there s an aerobatic subject that can challenge the thrill of the Goldberg Ultimate it s this Extra 300 The Extra s generous moments light wing loading and strong airframe make it an excellent airplane for the aerobatic pilot whether he is learning his first maneuvers or is an unlimited class competition flyer Yet with all it s aerobatic potential this is still a very well behaved aircraft making takeoffs and landings a breeze And when it comes to engines please note bigger is not better A good 60 will do an excellent job A larger than recommended engine may overly stress your model causing structural failure WARNING A radio controlled model is not a toy It is capable of causing serious bodily injury and property damage It is the buyer s responsibility to build this kit correctly and to properly install the motor radio and all other equipment The first test flights should be made only with the assistance of an experienced R C flyer The model must always be operated and flown in accordance with the safety standards of the Academy of Model Aeronautics Per the Federal Communications Commission you are required to use only those radio frequencies specified for Model Aircraft Pt 42060 8 97 Copyright 1991 ITEMS NEEDED TO COMPLETE THIS KIT
6. SOLDER 10 30 60 90 DRAFTING TRIANGLE INTRODUCTION USING THIS INSTRUCTION MANUAL Before you start gluing and sanding take some time becoming familiar with the plans and looking through this entire Instruction Booklet It is designed to guide you through the construction process step by step so build in the order given in this book Balancing setting up and flying the model are also covered Like a full size airplane the Extra 300 is built from basic structures stabilizer fin wing etc which are then assembled into the complete airplane Special procedures or comments will usually be explained before a step so you will be prepared If a step begins with a statement like Note Warning or Important it is a good idea to read through the step before doing it A check off box appears at the beginning of each step Check these boxes as you build so you can tell at a glance what steps you have completed Some steps are repeated and must be marked twice as in the case of the left and right wing panel Some of the instructions deal with general procedures Boxes are not needed for these sections HOW TO READ THE PLAN There are two plan sheets in this kit Showing the Fuselage Body the Wing and the Tail Parts Everything on the plan is drawn to full size and shape and shows how the finished parts fit together The plan is drawn to show the model completely assembled but as a result the area
7. Test bolt the wing to the fuselage and check to make sure the tip to tail dimensions are still equal Trim and glue the 1 2 balsa triangle stock behind the firewall Glue in the top reinforcement Glue in the remaining triangle stock as shown 32 27 28 29 30 0 Locate Former at 900 angle to the front reinforcement and glue Glue one edge of the 1 32 ply TOP SHEET to the fuse Then using a spray bottle to soak the sheet slowly roll to the opposite side gluing as you go MARKTHE CENTERLINE ONTHE TOP SHEET AND THE FUSE TO INSURE A CORRECT FIT Sand the edges in line with the firewall and Former BB Install Former FF directly above Form F and at a 900 angle to the fuse top Mark the centerline onto the horizontal stabilizer and on the stab platform of the fuselage Glue the stabilizer to the platform locating it on the centerlines and against Former FF Check the stabilizer to insure that it is parallel to the base 33 SOAK THE BEND 31 32 33 34 0 35 0 36 Install the vertical fin Insert the rudderpost into the rudderpost slot Tilt the fin forward until it rests on the top surface of the stab Check that the assembly is square using a 900 triangle Permanently glue the fin to t
8. 1087 1 D C SHT 5518 1 32 PLY PT 3481 CONTAINING 2 FAIRINGS 2 BALSA SHEET 1 16 x 2 7 8 x 10 PT 4886 5518 3481 Install the LANDING GEAR WIRES and secure them in place with the nylon straps and screws 3 8 SCREW Tack glue the plywood FAIRINGS to the wire gear Align the half moon notches with the wire and keep the root end parallel to the fuse bottom Edge glue the two 1 16 x 2 7 8 x 10 BALSA SHEETS together and cut 9 1 2 cross grained strips 9 1 cross grained strips Laminate three 1 strips to the ply failing Wet the balsa if necessary to bend into position Repeat the process with the 1 2 strips on the front side of the fairing L Sand the completed fairings to shape You may want to remove the fairing from the wire to shape it After the fairings are covered or painted permanently attach them with silicon adhesive CONSTRUCTING THE CANOPY FRAME 6 Steps Collect the following parts D C SHT 5503 REMAINDER PLY PT 43474 CONTAINING 2 RAILS Gite D C SHT 5505 REMAINDER PLY PT 3476 a 1 CONTAINING 2 FORMER CC 2 5503 3474 D C SHT 5508 REMAINDER PLY PT 43479 CONTAINING 1 SPREADER DOWEL 1 4 x 1 3 4 BIRCH PT 1755 CANOPY PT 9515 COCKPIT INSERT PT 49518 4 40 BLIND NUT PT 1125 4 40 x 1 2 PAN HEAD SCREW PT 1048 2 WASHER P
9. 5520 3332 2 REQ D 5 16 x 5 16 16 BALSA 8 REQ D 5 16 x 5 16 x 20 BALSA 1 REQ D T E STOCK 2 REQ D 3 8 x 1 2 x 2 1 4 BASSWOOD HORIZONTAL STABILIZER CONSTRUCTION 5 Steps 1 Collect all of the items you will need to construct the HORIZONTAL STABILIZER They include 1 sS HINT 3 16 x 5 16 BALSA D C SHEET 5517 3 16 BALSA PT 1331 Includes CENTER PLATFORM 3 16 x 5 16 X 28 BALSA STICKS PT 4371 1 16 x 3 x 30 BALSA SHEETING PT 4539 V S J 5517 3331 Lay the horizontal stabilizer portion of the plan over the building board and place the waxed paper over the plan You will also need T pins an X Acto knife with 11 blade and a razor saw Pin the CENTER PLATFORM over the plan Cut a 3 16 x 5 16 balsa stick and glue it to the platform with medium CA pinning it over the plan Trim the remaining 3 16 x 5 16 balsa sticks to fit the plan pinning and gluing as you go In cutting the diagonal trusses for the tail trim them to fit well If a bit oversize don t force them in place The pieces should fit before gluing Place a 1 16 x 3 x 28 balsa sheet flush to the trailing edge T E of the stabilizer and mark the sheet width onto the stab sticks In selecting the sheeting for the stab choose the firmer or heavier wood whenever sheeting any surface is helpful to lightly sand both sides
10. C 5516 3483 1 DOWEL GUIDE PLY D C 5509 3480 2 INBOARD T E BALSA MIL 4526 5 1 16 x 1 4 x 24 CAPS BALSA STK 4525 2 AILERONS BALSA MIL 4527 6 1 16 x 2 3 4 x 35 BALSA SHT 4888 4 1 16 x 2 1 2 x 35 BALSA 5 4887 1 3 4 x 38 NYLON FABRIC NYL 5210 1 5 16 x 4 3 4 DOWEL BIRCH MIL 1759 2 063 x 20 3 4 AILERON WIRE MTL 1230 2 063 x 7 THREADED ROD MTL 1270 2 AILERON BELCRANKS NYL 1410 2 AILERON BUSHINGS MTL 1182 2 2 56 NUT MTL 1115 2 2 56 x 1 2 MACHINE SCREW MTL 1041 2 2 WASHER NYL 1461 4 NYLON SNAP NUT NYL 1138 3 1 16 I D x 1 BRASS TUBE BRS 1376 1 AILERON COUPLER BLOCK NYL 1427 1 2 56 x 3 4 MACHINE SCREW MTL 1042 1 2 56 x 1 8 MACHINE SCREW MIL 1040 1 SNAP LINK NYL 1405 8 FLEX POINT HINGES NYL 1449 1 C G CENTERLINE TOOL NYL 1425 13 5511 3326 5512 3327 5514 3329 am ma NN 5515 3330 11111 5520 3332 AILERON STOCK 1 6 x 1 4 x 24 NOTCHED T E BALSA 3 8 SQ BASSWOOD IS Ni SHAPED L E BALSA NOTE IF USING AN ENGINE LARGER THAN A 60 2 CYCLE YOUWILLWANT TO FOLLOWTHE INSTRUCTIONS FORTHE TWO SERVO OPTION WHICH ARE FOUND IMMEDIATELY AFTER THE WING SECTION NOTE YOUWILL BE BUILDING TWO WING HALVES DO NOT BUILD BOTH HALVES OVER THE SAME SECTION OF THE PLAN FOLLOW STEPS CAREFULLY TO AVOID CONFUSION 2 Cutthe vying plan along the dotted line Posi
11. CONTAINING HATCH COVERS 16 2 x 5 16 SHT METAL SCREW PT 1086 16 2 WASHER PT 1138 1 Ez 5521 3484 5522 3334 24 2 Laminate the two ply front platform supports and glue to the spar centering between Ribs 6 and 7 Glue the rear platform support to Ribs 6 and 7 and to the T E sheeting MEM 3 Drilla1 16 diameter hole in each corner of the platform and mount to the rails using four of the 2 x 5 16 Z screws and washers LZ 4 Gluethe corner gussets to the servo mounts and fasten the assemblies to a servo E GUSSETS 5 Glue a corner gusset to each corner of the servo bay as shown Fabricatethe balsa hatch and drill a 1 16 diameter hole in each corner 1 Center the servo arm in the slotted hole of the hatch cover to locate the servo Remove the hatch and glue 2 x 5 16 WIWASHERS lt the servo gussets and mounts to the platform 6 After the wing is covered and with both the servo and aileron inthe neutral position measure and connect the pushrod THIS COMPLETESTHE WING NOW LET S MOVE ON TO THE FUSELAGE 25 CONSTRUCTING THE FUSELAGE 36 Steps 1 Gather all of the parts needed to construct the FUSELAGE They include 2 D C SHT 5501 PLY SIDES PT 3475 D C SHT 5502 PLY FUSE BOTTOM PT 3473 1 1 D C SHT 5503 P
12. of Rib 1 18 MARKS ALIGN WITH SPAR 20 Pin the right wing panel to the building board directly above the wing plan outline With the cut outs pointing down assemble the dowel support to one of the Rib 1 front sections BUT DO NOT GLUE With the dowel support assembly inserted into the fixed right wing panel slide the left wing half into position Sand and trim to fit as needed When satisfied with the fit pin the left wing to the board directly above the plan Lightly sand joiners and spars for maximum bond Then apply 20 MINUTE EPOXY to the wing joiners and insert into the wing around the spars Clamp to form a gap free joint Check to see that the wing is firmly on the fixtures while the joiners are drying Laminate the rear portion of Rib 1 IFYOU ARE PLANNINGTO USETHETWO AILERON SERVO SYSTEM DO NOT PUNCH OUT THE CENTER MOUNTED SERVO BLANK AS SHOWN HERE GLUE IT IN PERMANENTLY Install the rear portion of Rib 1 directly over the centerline and glue Trim to fit if needed OMIT THE FOLLOWING STEP IF BUILDING THE TWO SERVO OPTION Install and glue the servo mount into the slots in Ribs 2 and onto Rib 1 22 Drill a 5 16 diameter hole at the center mark of both discs Then slide the dowel through the Leading Edge the support and the dowel guide Insert the remaining fron
13. sure that you correctly install Rib 7 as shown Match the bellcrank support slot direction to Rib 6 15 Position the shaped L E onto the support tabs Make sure that the beveled notched end is in line with the wing centerline Use a drafting triangle to project the wing centerline to the L E end Using the set back gauge for correct positioning gently slide the top spar into the rib notches SET BACK GAUGE Check the wing alignment with the plan underneath Then place a drop of Jet glue at each joint along the Leading Edge the Spar and the Trailing Edge Glue the balsa shear webs to the front side of the spars centering the shear webs between the wing ribs IF YOU ARE USING THE TWO AILERON SERVO SYSTEM OMIT THE FOLLOWING Drill a 1 16 diameter hole at the center mark on each USE THE TWO AILERON SERVO OPTION IF USING AN of the aileron bellcrank supports and glue the support ENGINE LARGER THAN A 60 2 CYCLE between Ribs 6 and 7 Edge glue two sets of three 1 16 x 3 x 36 balsa sheets Measure 3 5 16 from opposite edges as shown and mark Cut along the line established by the two marks Repeat this process on the other glued sheet This gives you the L E sheeting for the entire wing 3 5 16 Se 16 bs Position a full sheet edge against the L E shoulder Align
14. the corner with the L E centerline end and roll onto spar Mark the sheet in line with the top spar end and cut along the line formed Use this sheet as a template to cut the other three L E sheets Glue the L E sheeting to the L E shoulder ribs and Spar pinning or taping to secure until dry Glue the 1 16 x 2 1 2 x 36 Trailing Edge sheeting to the notched T E and the wing ribs To glue the center sheet in place first install the front and back pieces Then slide the center piece in tightly Trimming may be necessary Place some glue on the wing tip sheeting and slide in place Cut the 1 16 x 1 4 balsa capstrips to fit and glue to the wing ribs Trim the sheeting along the wing centerline 15 Glue the pretrimmed Trailing Edge part to the wing Align the angle cut side with the notched T E Make sure the top of the T E and the wing sheeting are flush over the entire length REMOVE THE WING PANEL AND GO BACK TO STEP 8 MAKING SURE TO WORK OVER THE OTHER HALF OF THE WING PLAN REPEAT THE CONSTRUCTION SEQUENCE FOR THE OTHER WING PANEL AFTER COMPLETING STEP 15 FOR THE SECOND TIME GO ON TO THE NEXT STEP TIP FIXTURE CENTERLINE 16 Glue the front rear and tip wing fixture supports as shown 17 O Locate the wing fixtures and pin to the plan Align the marks on the tip fixtures to the spar on the plan 18 Laminate the top and bottom portions
15. triplers onto the wing saddle doublers Make sure that the landing gear wire slots are in line 9 With the triplers face to face tape the fuselage sides together at the rudderpost end Use a scrap piece of 3116 balsa spacer between the sides Install Former D balsa doubler forward and secure with a rubber band Install Formers E and using rubber bands to secure at each former 10 O Slide the fuselage top under the rubber bands and press into position Loosen the tape at the rudderpost end to allow top to fit 11 Slide in the SLANT former 12 Flip the fuselage over and install the bottom sheet Position the fuselage over the TOP VIEW of the plan and check the alignment Use small pieces of masking tape to secure the structure as you go Sight check down the fuselage to insure against twist LIKE THIS NOT THIS 13 O When the fuselage is perfectly aligned glue all of the seams created by the sides top bottom and formers Glue the landing gear block to the fuselage assembly Make sure the groove is facing out Glue Former C to the landing gear block and the triplers Glue in Former B Check that the former is flush with the fuse side slot Glue the FIREWALL onto the fuselage assembly Make sure that the blind nut flanges are on the inside Glue the bottom front piece in place
16. AR GUSSET SHEET 5508 3479 1 REQ D LANDING GEAR FAIRING WING DISCS RIB 2 RIB 8 SHEET 5510 3325 2 REQ D HORN MOUNT DOUBLER ELEV SHEET 5509 3480 1 REQ D SHEET 5518 3481 1 REQ D RIB 3 RIB 6 SHEET 5511 3326 2 REQ D RIB 9 O O n C2 c SHEET 5514 3329 2 REQ D RIB 1 RIB 10 HORN MOUNT RUDDER CENTER PLATFORM GUSSETS HORN MOUNT ELEV SHEET 5517 3331 1 REQ D MOUNTING RAILS REAR MOUNTING RAILS FRONT SERVO MOUNTS SERVO PLATFORM SHEET 5521 3484 1 REQ D GUSSETS BALSA 3 REQ D 3 16 x 5 16 x 28 BALSA 5 REQ D 1 8 x 1 2 x 18 BALSA 2 REQ D 1 16 x 1 4 x 24 BALSA 5 REQ D 1 2 X 7 3 16 x 5 16 x 16 TRI STOCK 1 REQ D RIB 4 RIB 1 coe SHEET 5512 3327 2 REQ D WING TIP SHEET WING CENTER SHEETING SHEET 5515 3330 4 REQ D SANDING GAUGES SERVO TRAY PUSHROD SUPPORT SET BACK GAUGE SHEET 5519 3482 1 REQ D HATCH FRONT HATCH REAR SHEET 5522 3334 1 REQ D SHAPED L E 2 REQ D NOTCHED T E 2 REQ D 3 8 SQ X 35 BASS 4 REQ D RIB 5 RIB 7 SHEET 5513 3328 2 REQ D BELCRANK PLATFORMS L E FIXTURE TIP FIXTURE ne ee o 2 j FIXTURE SERVO PLATFORM DOWEL SUPPORT SHEET 5516 3483 1 REQ D HORN MOUNT DOUBLE ELEV SHEAR WEBS M2 HORN MOUNT DOUBLER RUDDER SHEET
17. After 4 or 5 snaps the Extra will be ready to fly out straight and N N level FULL DOWN N KNIFE EDGE SPIN PA A unique maneuver to observe so here s what to do ENTER A CONVENTIONAL SPIN p y FULL LEFT RUDDER AND FULL LEFT AILERON FULL UP AFTER 1 OR 2 TURNS The plane will go into a knife edge spin and will lose altitude very quickly so be advised FULL DOWN 42 g Tee ah SAILOR dOL NOLLOG ORI e Z SUUM 901 z anig IO 10l0O xoe g sieAuf eoejed 1 Agueno 02 HEIS 1 odor seupuoe d seeJfeq 02 a 1 euuM 90 g enig 15 100 xyoe g sJeAuuf eoejed a 9994890 0 5 00 8 16u 1 s uou GZ seuou 52 1461H u pers 6 9 SILIO eis exse M gt 8 y sepis z Aguen MIA 3QIS g enig 1009 piog sues eoejed 92 9 16 9 5 69 8 sepis z Ayueno ALIHM M enig 009 plog sueS 3 SZ SHO 109 921 3uDieH SNOILVOOT 1V23G 3IN3HOS 40109 43 For your next
18. LY PT 3474 CONTAINING TOP amp BACKUPS 5502 3473 1 D C SHT 5504 PLY PT 3475 gt CONTAINING DOUBLER TRIPLER FORMERS amp FUEL TANK TRAY lt 1 D C SHT 5505 PLY 3476 CONTAINING DOUBLER TRIPLER amp FRMRS 5503 3474 5506 3477 1 D C SHT 5506 PLY FRMRS 8 GAUGES 3477 1 D C SHT 5507 PLY FORMERS PT 3478 1 D C SHT 5508 PLY FORMERS PT 3479 1 D C SHT 5509 PLY FIREWALL PT 3480 26 622 1 D C SHT 5518 PLY TURTLEDECK 129 2 1 1 32 PLY FRONT TOP SHEET PT 4602 1 BASS WING MOUNTING BLOCK 4372 5504 3475 07 3478 1 1 4 PLY LANDING GEAR BLOCK PT 4373 5507 2 BASS MOTOR SPACER PT 4374 1 1 2 x 7 BALSA GUSSET PT 4217 2 1 8 1 2 x 18 BALSA STICK PT 4376 6 6 32 BLIND NUT PT 1124 6 6 32 x 1 1 4 SOCKET HD SCREW PT 1024 2 6x3 4 WASHER PT 1144 5505 3476 6 x 3 4 SHT METAL SCREW PT 1082 2 MAIN LANDING GEAR WIRE PT 1322 2 MOTOR MOUNT PT 1466 0505 5518 3481 5501 3472 1 2 x 7 BALSA 1 8 x 1 2 x 18 BALSA BASS SPACER 2 Carefully remove the parts from the die sheets and lightly sand the rough edges of each part 3 O With the scribe lines exposed glue FIREWALL FORMER to the other firewall half Make sure the top and side edges match Note the bottom offset fit Tape together and allow the assembly
19. Men removing parts such as fuselage sides from the die cut sheets Long parts are fragile until glued into a structural unit If necessary use a razor knife or razor saw to assist in the removal of parts from the sheet Sometimes a little trimming and sanding can improve parts Mere desired Save scrap until the model is completed in case a part is missing or damaged Also scrap is used in some building steps SHEET 5502 3473 1 REQ D TANK TRAY FORMER F LANDING GEAR TRIPLER FORMER WHEEL PANT SUPPORTS AXLE SUPPORTS SHEET 5504 3475 1 REQ D BOTTOM FRONT FORMER TOP REINFORCEMENT ELEVATOR GAUGE RUDDER GAUGE SHEET 5506 3477 1 REQ D FORMER SHEET 5507 3478 1 REQ D FIREWALL FORMER E ABOUT THE WOOD IN THE KIT We strive to supply good quality materials in your kit Wood parts are inspected with regard to the function they will serve If an imperfection is spotted in a scrap corner of a die cut sheet and doesn t affect actual parts the sheet is considered acceptable Also internal stresses in wood are relieved as it is cut into parts These relieved stresses may cause some parts to bow Bows in wood parts such as leading edges readily straighten out as they are glued into a structural unit SHEET 5503 3474 1 REQ D FORMER 2 FORMER BB LANDING GEAR TRIPLER SHEET 5505 3476 1 REQ D FUSELAGE DOUBLER REAR SPREADER SLANT FORMER RE
20. ONTAINING 1 16 HORN MOUNT Laminate the three horn mounts as shown making sure that the 3 16 horn mount is in the middle 5 16 x 516 BALSA MN CI 5517 3331 EXHI 5520 3332 3 Cover the RUDDER portion of your plan with waxed paper and pin the laminated horn mount assembly over the plan 4 Trim glue and pin the 5 16 square balsa sticks over the plan as shown NOW GATHER THE HORIZONTAL STABILIZER THE ELEVATOR HALVES THE FIN AND THE RUDDER AND PROCEED TO THE NEXT SECTION ROUNDING AND HINGING ROUNDING amp HINGING 11 Steps 1 Collect all of the items needed to complete this section In addition to the following kits parts you will need a small drill drill bits a modeling knife a sharp pencil a sanding block and fine and medium grit sandpaper 9 JET HINGES PT 1667 1 D C PLY SHT 5519 PT 3482 CONTAINING 1 ROUNDING TOOL 1 R BEVEL TOOL 1 BEVEL TOOL 1 CG NYLON CENTERLINE MARKER PT 1425 2 From the plan transfer the hinge locations onto the rudder and the elevator halves Next transfer the hinge locations from the rudder to the fin and from the elevators to the stab NOTE Leave a 1 16 gap between the air balance on both the rudder and the fin AIR BALANCE 10 Using the centerline tool scribe the centerline onto the rudder post the fin post th
21. T 1139 5508 3479 Mount the wing to the fuse Position the two rails on top of the wing as shown Tape to the wing if you wish SEE PLAN FOR SPACING REAR SPREADER Referring to the plan for the distance between the two Formers CC glue them to the rails Use the 1 4 dowel as an alignment pin to the fuselage Former BB Install the rear spreader into the slots in the rails and glue 4 40 3 8 Drill a 3 32 hole through the rail and the fuselage tab Press a blind nut into each tab and temporarily bolt the canopy frame to the fuselage 3 32 BIT 36 Pretrim the back flip up portion of the cockpit insert Glue the top of the frame and place the insert in position Trim the insert flush with the outside of the rails Add control sticks and pilot both not included in kit if desired Also paint the interior at this time Trim the canopy along the scribe line You may want to trim it a little long and precisely fit it to the wing and fuselage Paint the canopy deck up to the canopy crease ASSEMBLING THE WHEEL PANTS 6 Steps Clean up the edges of the pant halves by gently sliding them over sandpaper on a flat surface On both the outer and the inner pant half drill a 3 16 hole at the axle location Glue the two support plates to the inner pant half Glue the axle support plate to the outer pant half aligning the center m
22. ark on the plate concentric with the hole Rough cut the wheel opening in all four pant halves Then glue an outer half to an inner half forming a lap joint Align the outer half edge to the scribe line on the inner half all around 37 Carefully trim to the wheel well line Use a small round file to clean up the edges Fill the step of the lap seam with filler and sand smooth Repeat if necessary Repeatthe process for the other wheel pant When both are finished to satisfaction paint Slide the wheel pant collar wheel and other collar onto the landing gear axle Snap the landing gear into the pant groove and permanently install the nylon strap With the wheel in the center of the pant tighten set screws in the collars allowing the wheel to spin freely Install the tailwheel bracket Secure using two 2 x 3 8 Screws With the horn bracket on the wire notch the bottom of the rudder and glue in the bracket Install a 1 1 4 diameter wheel Carefully cut the cowl halves along the scribe lines around the perimeter Sand the edges straight along the top and bottom seam line Don t forget the cowl exhaust area 38 2 x 3 8 SCREW e 32 x 3 8 SCREW Cut the front piece along the scribe line around the circumference Cut out the two air intake openings on each side of the spinner ring along with the bottom opening a
23. control surface travel gauges supplied in this kit on D C SHEETS 5503 and 5506 The gauges provide two settings GENTLE response and a quicker AEROBATIC mode Even if you are a proficient flyer we encourage you to start out with the gentle marks and work up to the aerobatic settings This will give you an opportunity to experience the different travel responses AILERON GAUGE Place the gauge at Rib 10 wing tip to measure aileron travel Equal movement up and down Note the GENTLE and AEROBATIC setting marks ELEVATOR GAUGE With the point point locate the gauge at the tip of the horizontal stab The travel movements are not the same up and down Note the GENTLE and AEROBATIC setting marks RUDDER GAUGE Locate the gauge at the air balance space Flip the gauge to the opposite side to check opposite travel Note that there is only one setting for rudder JL Ss 5503 3474 Note the arrow points up 2 SETTING UP AND FLYING THE EXTRA 300 SETTING UP Time spent in setting up pays big dividends during your first flights Some flyers prefer VTR on flying surfaces Mile others prefer EXPO If you choose EXPONENTIAL start with 25 and adjust from there Set the throws to the higher setting and use the EXPO to soften the neutral For VTR inhibit the dual rate but set as follows AILERON 65 ELEVATOR 65 Note again that the max throws are in the high position
24. e all of the dust when finished Starting at the front of the servo cut out completely wrap the center of the wings with 3 4 nylon tape Smear glue through the fabric weave using a plastic bag to protect your finger Trim the excess at the rear servo cut out 35 0 NOTE At this time transfer hinge locations from the plan to the ailerons Next transfer these marks to the wing Be sure to leave a 1 16 gap between the aileron and the T E center section 116 SPACE Use centerline tool and scribe a hinge centerline into both ailerons and wing halves Hinge the ailerons just like you did the elevator and rudder Bevel the ailerons to the center scribe line using the bevel tool marked AE Temporarily hinge the ailerons to the wing to test the fit Then sand the aileron to the tip plane of the wing Permanent assembly of the ailerons to the wings as well as control horn installation is done after covering IF YOU ARE INSTALLING ONLY ONE SERVO THE WING CONSTRUCTION IS NOW COMPLETE TWO SERVO SYSTEM CONSTRUCTION 6 Steps TO BE INSTALLED ON A COMPLETED WING NOTE The two servo option should be used for aircraft using an engine larger than a 60 2 cycle 1 Collect the following parts needed to install an aileron servo in each wing panel 1 D C SHT 5521 PLY PT 3484 CONTAINING SERVO MOUNTING PARTS 1 D C SHT 5522 BALSA PT 3334
25. e hinge line of the stabilizer and onto both elevators Carefuly cuta slot approximately 1 2 deep and slightly wider than the hinge using your favorite knife blade After all slots have been made mark the center of your hinge and insert a pin see illus This will hold the hinge in place while sliding the matching part aileron etc onto the JET HINGE DO NOT GLUE With both surfaces hinged and assembled check the alignment For good control response the hinge gap should be as small as possible but should allow for full deflection when needed Remove the hinges Assemble the two bevel tools and install a strip of medium grit sandpaper as shown Using the tool marked R bevel the rudder side of the hingeline to a point at the centerline You may want to bevel near the air balance with a knife if you can t use the tool in the corner Using the tool marked AE bevel the elevators to a point at the centerline Temporarily hinge the rudder fin and the stab elevators to check the surface alignment and to round the perimeter of the assemblies 11 HINT Assemble the Rounding Tool and install a piece of 2 PLATFORMS medium sandpaper 2 FORMERS SANDPAPER Using the tool round the perimeter of the fin rudder and the stab elevators When you are satisfied with the shape use a piece of fine sandpaper to remove the deep scratches Finish sand all of the
26. he stabilizer and fuselage Glue the ply BACKUP pieces to the stab on each side of the fin Slide the 1 32 ply turtledeck around the fin With a water spray bottle liberally soak the top centerline of the turtledeck This will allow the plywood to be formed without splitting Wrap the ply around the formers and down onto the fuselage sides Sand the sides for a smooth fit When satisfied with the fit apply glue to the formers fuselage sides fin and stab Quickly wrap the plywood down to the fuselage and tape in place until dry Bevel the plywood edge at the fuselage lap joint and sand the edge flush with the slant former Fill the step with CGM Model Magic filler Apply additional filler to the fin and stabilizer seams and blend to create a smooth transition Go over the fuselage sanding all seams and joints with medium sandpaper Then sand the entire fuselage with fine grit sandpaper The effort you put into finish sanding will show as no covering material will hide a poor sanding job FILLER Now go back to all of the built up parts to inspect the sturdiness of joints and to finish sand When satisfied with the finish the aircraft is ready for covering CONSTRUCTING LANDING GEAR FAIRINGS 7 Steps Collect the parts needed to construct the LANDING GEAR FAIRINGS They include 2 LANDING GEAR 3 16 WIRE PT 1322 2 LANDING GEAR STRAP PT 1418 4 2 x 3 8 SHT METAL SCREW PT
27. mble the aileron coupler 21 1 16 1 0 x 1 BRASS TUBE 29 30 Slide one 1 16 ID x 1 brass tube onto the left aileron pushrod and one tube onto the right aileron pushrod Slide the aileron coupler assembly onto both pushrods The coupler block should be centered on the wing centerline Check that the bellcranks are still fixed in the neutral position and solder the coupler tube to each pushrod The other brass tubes will be positioned after the servo is mounted Connect the aileron servo to the pushrod Locate the servo so that the bellcranks are in the neural position Tighten the setscrew and mount the servo In each wing half center the brass tubes on the aileron pushrods at Rib 4 Glue the horseshoe shaped balsa piece retained from Step 7 to Rib 4 laterally locking the brass bushing in the wing 31 32 33 0 34 0 Cut out the opening for the aileron servo as you install the center sheeting IF YOU ARE USINGTHETWO SERVO OPTION CUT A SMALLER OPENING FOR SERVO LEAD ACCESS ONLY Glue the tip sheeting in place and install the capstrips Remove the wing assembly from the building board Sand flat the end ribs and glue the balsa tip rib to both tips Sand the perimeter to match the airfoil Sand the wing blending all the seams and joints Use a tack rag to remov
28. n the outline or size will not noticeably affect flight performance Because the fuselage plugs together and is self aligning it is not built directly over the plan As you assemble the fuselage you will find the plan helpful in identifying parts and how things fit together The plan also shows the installation of a typical radio battery and all remaining equipment and hardware needed to complete the model By referring to the examples shown you should be able to install your own radio etc even if it is not the same as what is shown on the plan IDENTIFYING PARTS Parts for the wing are bundled together likewise parts for the tail assembly are also grouped Die cut plywood and balsa sheets of common sizes are bundled together so they are less likely to be damaged during shipping and handling The various screws hinges and fittings are packaged in plastic bags PREPARING FOR ASSEMBLY Set a flat warp free pinning board on your work bench Any material that accepts pins such as insulation board soft plywood or dry wall sheet rock will work Important any warps or bends in the pinning board will result in wings or tail surfaces that are also warped or bent making your model more difficult to fly Make sure that the pinning board is flat by laying a straight edge across it You may be able to correct a warped board by shimming its low areas Position the area of the plan such as the stabilizer on which you are going t
29. nd the prop shaft opening Use a small round file to lean up the edges of each intake Glue the front piece onto one of the sides Glue the joiner strip to the top and bottom seam Leave half of the strip width exposed to allow a gluing surface for the other cowl half Glue the remaining half to the front piece and onto the joining strip Fit all seams as tightly as possible This will eliminate excessive filling and sanding Fill the seams with filler and sand smooth Paint the cowl with a good quality fuel resistant paint Permanently install the motor mounts to the firewall using four 6 32 x 1 1 4 socket head screws with washers If you are not using the engine spacers you must cut the screws so they do not interfere with the fuel tank Don t forget right thrust Screw the engine to the mounts using four 6 x 3 4 screws with washers Slide the cowl on over the engine and install the spinner backplate on the prop shaft Allow a 1 16 space between the backplate and the cowl Locate the cowl off the spinner backplate and attach to the fuselage using four 4 40 x 3 8 screws and washers See plan for locations If you prefer to install fiberglass rather than plastic parts these may be obtained directly from Carl Goldberg Products See ordering information on the Parts List 1 16 SPACE ALL AROUND 39 3 32 BIT FUEL TANK INSTALLATION 3 Steps 1 Rubber band the tank to the platform 2
30. o build over the pinning board and tape it in place so the plan lays flat and wrinkle free Place a sheet of waxed paper or plastic kitchen wrap over the work area to prevent the C A glue from sticking to your plan and ruining it CONSTRUCTION TIPS In assembling your model the following tips will prove helpful IMPORTANT ALWAYS READ A FEW STEPS AHEAD This will alert you to coming instructions and will help you plan accordingly You may find it convenient to empty all of the small parts from the hardware bags into a common container such as a margarine tub This will help you find items quickly When drilling any 1 16 holes in balsa you may find it easier to twist the drill between your thumb and index finger This procedure allows more control in positioning the drill on the center mark Punch out only the die cut D C parts you need as you proceed This will help you keep track of parts especially the small ones After completing each section of the aircraft you may want to go back and reglue the joints just in case some area has been missed Be careful not to use too little glue which will leave the model weak or too much glue which can make the model heavy Properly glued joints are important to the overall strength of the model Medium C A glue is recommended for most parts of the assembly although Jet Epoxy may be used when more time is needed for careful placement PARTS IDENTIFICATION WOOD PARTS Be careful
31. of the sheet before using medium C A Also whenever joining sheeting truing the edges to be glued with a long sanding block and prefitting can make a big difference Remove the sheet and apply medium C A to the stab sticks up to the sheet width mark Place the glued stab frame over the 1 16 sheeting making sure that the trailing edge is flush with the sheet Glue the remainder of the stab frame and install another 1 16 balsa sheet Then trim the sheeting to the profile of the stab Spin the cut off around and glue to the remaining space on the frame SPIN AROUND Flip the stab over and sheet it as shown above THIS COMPLETES THE HORIZONTAL STABILIZER PUT IT ASIDE FOR NOW YOU WILL NOT NEED IT UNTIL YOU ARE READY TO INSTALL THE HINGES ELEVATOR CONSTRUCTION 4 Steps Collect all of the parts needed to build the two ELEVATOR HALVES They include 5 16 sq x 16 BALSA STICKS PT 4370 BIRCH PLY D C SHT 5518 CONTAINING 4 HORN MOUNTS PT 3481 D C BALSA SHT 5520 CONTAINING 2 HORN MOUNT CORES PT 3332 5518 3481 D C SHT 5517 BALSA CONTAINING 1 BALSA CORNER GUSSETS PT 3331 1 BALSA HORN MOUNT CORES PT 3331 ud r 5 16 SQ BALSA 5520 3332 J 5517 33 31 Laminate the two 1 32 PLYWOOD HORN MOUNTS to the 3 16 and 1 16 BALSA CORES Make two such assemblies one for each elevator half
32. on the travel gauges which is a good starting point From there adjust to personal taste Balance is very important as too far forward will cause the aircraft to want to nose over on takeoff particularly in grass Balance that is too far back will make the aircraft pitch unstable and difficult to control Balance CAREFULLY reference the plans Start with the forward location and add tail weight carefully FLYING TIPS 41 This EXTRA is very easy to fly if properly set up On take off the plane has excellent stability but it will feel nose heavy Always use full up elevator when taxiing to prevent nosing over Keep first flights short and check the aircraft often Landing is quite straight forward The plane is clean and will glide well However it won t snap unless rudder is applied Try to land in a 3 point configuration and Men the mains touch release some of the used in the flair This will eliminate the bounce on landings In knife edge the EXTRA will take some opposite aileron flight to keep the wings perfectly vertical It can be hand flown or with a computerized radio automatically mix in the correction Mix 496 opposite aileron for rudder direction used No elevator mix is required SETTING UP AND FLYING THE EXTRA 300 FLYING SNAP ROLLS Pull up and climb at 45 degrees and go to knife edge M B gt 50 RUDDER THEN FULL RUDDER AND FULL AILERON FULL UP AFTER 1 1 2 SNAPS
33. s inside or underneath are covered up making it hard to understand how these parts fit together Therefore for clarity some parts are drawn with hidden lines others with breakaway views and some are entirely removed from the structure and shown separately For example on the fuselage the left side of the completed model has been removed to show the details inside Sometimes a surface is broken away to reveal the detail behind or underneath Dashed lines indicate details that are hidden behind or under another part of the surface The model is made from four varieties of wood balsa bass birch and various plywoods Each kind of wood has its own characteristic end grain pattern as viewed from the end which has been drawn on the plan You can easily use these end grain patterns to identify what kind of wood is shown for a part if you are in doubt HOW TO USE THE PLAN The plan is used in several ways The wings stabilizer and fin are assembled directly over the plan Each wood part is matched over its corresponding location printed on the plan and pinned in place To prevent ruining your plan from gluing your wings etc to it cover the area you are working on with waxed paper The paper the plan is printed on can expand or contract slightly with changes in temperature or humidity Because of this a preformed part such as the notched wing trailing edge may not exactly match the plan This is no problem as slight deviations i
34. t portion of Rib 1 onto the dowel Generously EPOXY the entire front rib area as well as the dowel support tabs in Rib 2 23 Crack off all of the support tabs Glue the remaining pretrimmed L E sheeting to the wing Pin or tape to secure until dry 1 Fit and trim the sheeting and glue to the wing NOTE IF YOU ARE USING THETWO SERVO OPTION GO ON TO STEP 31 24 Bend a 5 16 x 900 angle at one end of the 063 SNAP NUT diameter x 20 3 4 wire pushrod Install an aileron bellcrank onto the bend See plan for correct orientation Secure with a snapnut Place a drop of JET glue on the snap nut 20 Slide the pushrod assembly through the openings in the wing ribs from Rib 6 toward the center 0 08 2 56 1 2 MACHINE SCREW 7 Install the hardware to mount the bellcrank to the BELCRANK j platform BUSHING 2 WASHER 2 56 NUT 25 O Using the plan for reference cut the aileron pushrod exit holes in the T E sheeting 1 4 x 90 DEGREES 26 Make to pushrods to fit the template shown here SNAP NU 27 Install the threaded pushrods onto the bellcranks and secure with snap nut Place a drop of JET glue onto NY the snap nuts Referring to the plan fix the bellcranks in the neutral position with a T pin 28 Asse
35. tail parts using a sanding block and fine sandpaper Sanding will cause gaps at the joints to fill with balsa dust Use this to your advantage by putting a drop of thin C A glue into the gap Then sand after the glue dries Separate the fin from the rudder and the elevators from the stabilizer THIS COMPLETES THE CONSTRUCTION OF THE TAIL SECTION PARTS PUT THEM ASIDE UNTIL YOU ARE READY TO ATTACH THEM TO THE FUSELAGE 12 CONSTRUCTING THE WING 35 Steps THE INSTRUCTIONS WILL LEAD YOU THROUGH THE ASSEMBLY SEQUENCE OCCASIONALLY SENDING YOU BACK TO REPEAT STEPS CAREFULLY READ EACH STEP BEFORE YOU PROCEED TO DO THE INSTRUCTION 1 Find all the parts that you will need to build the wing THEY INCLUDE 4 3 8 SQ X 35 SPAR BASS MIL 4528 2 SHAPED L E BALSA MIL 4524 2 NOTCHED T E BALSA MIL 4523 2 WING RIBS 2 amp 8 BALSA 4 2 2 2 D C 5310 3325 2 WING RIBS 3 amp 6 BALSA D C 5511 3326 2 WING RIBS 4 amp 1 BALSA D C 5512 3327 2 2 4 2 2 WING RIBS 5 amp 7 BALSA D C 5513 3328 2 WING RIBS 1 9 amp 10 BALSA D C 5514 3329 4 WING CENTER SHEETING BALSA D C 5515 3330 SHEAR WEBS BALSA D C 5520 3332 2 WING JOINER PLY 2 BELCRANK PLATFORMS PLY D C 5516 3483 2 DOWEL SUPPORT PLY D C 5516 3483 1 WING SUPPORT FRT PLY D C 5516 3483 1 WING SUPPORT REAR PLY D C 5516 3483 1 WING SUPPORT TIP PLY D C 5516 3483 1 SERVO PLATFORM PLY D
36. tion the left wing plan overlapping the right plan aligning the arrows as shown Pin or tape the plan to the building board and cover with waxed paper 3 O Laya shaped LEADING EDGE over the plan and cut the angle at the centerline Repeat this step on the other L E 2 NOTCHED BALSA O Next place the notched TRAILING EDGE over the over the plan aligning the notches to insure that you cut the correct end Cut the angle at the centerline and then repeat this step on the other notched T E Referring to the plan cut the inboard T E parts to the correct length and angle CUT END 5 16 DOWEL 4 O Wrap a piece of fine sandpaper around the 5 16 NOV ASS DOWEL and sand the wing pin notch into the angle cut end of the shaped L E A SN 14 5 Scissors pin a 3 8 sq BASSWOOD SPAR over the plan as shown Make sure that the end is on the plan centerline 6 Pin tabbed Rib 2 6 and 10 over the plan but DO NOT GLUE at this time NOTE THE ANGLE OF THE SLOT 7 Place the notched T E on the support tabs with the cut end at the centerline Press the ribs into the notches and glue Remove the other ribs from their sheets IMPORTANT Save the horseshoe shaped punch out in Rib 4 as you will need it for Step 29 Place the remaining ribs into the notched T E and onto the spar but DO NOT GLUE Make
37. to dry on a flat surface Drill a 3 8 diameter hole at the center mark 26 Position the DRIVE WASHER of your engine over the drive washer on the plan SPACERS IF NEEDED Place the MOTOR MOUNT against the firewall over the plan You may require spacers to accomplish the proper position MINIMUM _ Tack glue the engine to the mounts MAKE SURE THAT THIS DIMENSION IS AT LEAST 1 4 If not use basswood spacers between the firewall and the motor mounts Place the motor assembly over the AF side of the firewall Measure 1 2 of the total distance between the mounts from the scribe mark on the firewall to one of the mounts n With the holes on the vertical scribe marks on the firewall mark all four mounting bracket locations 5 32 DRILL Drill a 5 32 hole at each location Turn the firewall over and insert the four 6 32 blind nuts Seat them with a soft hammer blow Coat the edges of the nut with JET GLUE Be careful to not get glue in the threads Put the assembly aside for now Locate glue and trim the 1 8 X 1 2 balsa doublers to the four formers F and the SLANT former 7 L Glue the wing saddle doublers to the inside of the fuselage sides Reference the landing gear block area REFERENCE POINT and the wing curve for the correct alignment 8 Glue the landing gear

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