3D AEROWORKS Extra 500 Guide

Assembly manual
and user guide
Extra 500
By 3D AEROWORKS

OVERVIEW:
This replica of the Extra 500 turbo-prop executive cruiser is designed for quick
and easy construction and printed using PLA. A semi-scale propeller and hub
is included in the plans designed to suit the 3536 1400kv outrunner in 2 or 4
blade configuration. Utilising full 5 channel controls; aileron, elevator, rudder,
flap and throttle. This model performs extremely well given its lightweight
design. Links to components used can be found on the last page of the user
guide.
GENERAL SPECIFICATIONS
WINGSPAN: 1000mm
PRINT WEIGHT: 790g
FLYING WEIGHT: 1100g - 1200g
ELECTRICS
MOTOR: 3536 1400kv
ESC: 50amp (recommended)
SERVOS: 9g
BATTERY: 2200MAH 3S (or similar)
INCLUDED
STL FILES OF ALL COMPONENTS
FACTORY FILES FOR SIMPLIFY 3D FOR PRINTERS: 200X200X200
**NOTE**
If using open source or free slicing software, scale all stl parts to 1000%
to attain proper sizing. Factory files for S3D have been scaled
appropriately

REQUIRED TOOLS:
KNIFE
SANDPAPER (MEDIUM GRIT)
PLIERS
CA GLUE
SCREW DRIVERS
FILE OR RASP
HOT GLUE GUN
DRILL
REQUIRED COMPONENTS:
X1 3536 1450KV motor (or similar)
X1 60AMP ESC
X1 2200MAH 3S LIPO (or similar)
X6 9g Sservo
X2 10mm X10mm X 2mm magnet (ROUND)
X14 16mm x 29mm nylon hinges
X4 M3 16mm screws
X2 M6 nylon bolt (length 30mm)
X2 M6 nylon nut
X2 1.2mm push rod (MIN LENGTH = 500mm)
x1 5x3mm carbon tube (OPTIONAL)
X1 3mm square carbon tube (50mm min length)
x1 1.2mm Linkage stopper
x1 m3 set screw
x3 45mm foam wheel (OPTIONAL)
Velcro
1mm push rod
3mm steel rod (x2 200mm + x1 95mm)

ASSEMBLY INSTRUCTIONS
1
All faces which are to be glued to other parts need to be given a light sanding
(scuff the surface) to assist with glue adhesion
FUSELAGE ASSEMBLY
2 (if using fixed gear, follow alternate steps 2a before continuing)
Glue the sections of the fuselage together using CA glue. With a sharp knife,
remove the floor of the battery hatch. (see pic, highlighted face in red)

2A
● Glue the nose gear washers in the slots provided in “fuse 2”.
external washer (smaller) internal washer (larger)
● Run a 3mm drill bit through the washers for the nose gear leg.
● Bend up a 95mm length of 3mm steel rod according to the following
diagram.
FRONT VIEW
● Fit a 1.2mm Linkage stopper to the steering arm.

● Install the nose gear leg with the steering arm and another m3 collar
locking the nose gear leg in the slot. (The hole in the side of the
steering arm is designed for a m3 set screw to secure the steering arm
to the gear leg, note- the hole should be pre-drilled with a 2.5mm drill
bit)
SIDE VIEW
TOP VIEW
● Glue fuse 2,3 and 4 together.
● Connect the steering arm to a length of 1.2mm wire and feed it through
the assembled fuse section. There is a small hole in the battery tray
floor to get a key through to adjust the wire on the steering arm.

3
Using either a soldering iron or 6mm drill bit, open up the holes in the top of
the fuse where the wing bolts will go through to connect with the nylon bolts.
(area to be removed highlighted in red)
Fit the nylon nuts into the slots provided at the rear wing join. secure with hot
glue or CA. (be careful not to fowl the thread with any glue)
TAIL ASSEMBLY
4
Glue the parts; “vertical stabiliser lower rear” and “vertical stabiliser middle
front” together using 3mm sections of skewer to align the parts. NOTE - leave
enough skewer protruding to align the top of the vertical stabiliser when it
comes time to fit it.
5

Glue the horizontal stabilisers to the vertical stabiliser assembly using 3mm
skewer.
6
Cut a 50mm section of 3mm square carbon tube and glue the elevators,
carbon tube and elevator control arm in place as shown. (note the position of
the control arm reference to the elevators)
7