AeroWorks 35cc EXTRA 300 ARF-QB User manual

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35cc EXTRA 300 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS
401 Laredo Unit “D”, Aurora, CO. 80011 - Phone [phone] - Fax [phone]
E-mail - [email protected]

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TABLE OF CONTENTS
Page
Aeroworks Contact Information ………………………………………………………………. 3
Introduction ……………………………………………………………………………………... 4
Kit Contents……………………………………………………………………………………… 5
Items Needed To Complete ……………………………………………………………………... 7
Tightening and Re-shrinking The Covering ………………………………………………….. 8
Check Seams and Overlaps for Good Seal ……………………………………………………. 9
Wing Assembly………………………………………………………………….……………….. 10
Stab and Elevator Assembly……………………………………………………………………. 14
Rudder and Pull-Pull Cable Assembly ………………………………………………………… 18
Tail Wheel Installation …………………………………………………………………………. 26
Main Landing Gear, Gear Cuffs, and Wheel Pants Assembly ……..………………………… 30
Engine and Throttle Servo Installation ……………………………………………………….. 35
Ignition Installation ……………………………………………………………………………... 48
Fuel Tank Assembly and Installation………………..…………………………………………. 52
Radio Installation ………………………………………………………………………………... 59
Muffler Installation ……………………………………………………………………………… 62
Cowl Installation …………………………………………………………………………………. 62
Preflight Preparation ……………………………………………………………………………. 68
Decal installation …………………………………………………………………………………. 71
Center of Gravity (C.G.) / Control Throws ……………………………………………. 75
Control Throw Deflection Table ………………………………………………………. 78

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401 Laredo Unit D
Aurora, CO 80011
Phone: [phone]
Fax: [phone]
Website: www.aero-works.net
E-mail: [email protected]
Thank you for choosing the Aeroworks 35cc EXTRA 300 ARF-QB. We put great effort
into making this plane the best model you will ever build and fly. We have provided you
with the highest quality kit and performance possible. We wish you great success in the
assembly and flying of your new Aeroworks 35cc EXTRA 300 ARF-QB.
!WARNING!
An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and property
damage. Fly only in open areas, and AMA (Academy of Model Aeronautics) approved
flying sites. Follow all manufacturer instructions included with your plane, radio,
servo’s, batteries and engine.
Aeroworks manufacturing guarantees this kit to be free from defects in both material
and workmanship at the date of purchase. This warranty does not cover any component
parts damaged by use or modification. In no case shall Aeroworks liability exceed the
original cost of the purchased kit. Further, Aeroworks reserves the right to change or
modify this warranty without notice.
In that Aeroworks has no control over the final assembly or materials used for final as-
sembly, No liability shall be assumed nor accepted for any damage resulting from the
use by the user of the final user-assembled product. By the act of using the user-
assembled product, the user accepts all resulting liability.
We, as the kit manufacturer, have provided you with a top quality, thoroughly tested
kit and instructions, but ultimately the quality and fly ability of your finished model
depends on how you build it; therefore, we cannot in any way guarantee the perform-
ance of your completed model, and no representations are expresses or implied as to
the performance or safety of your completed model.

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INTRODUCTION
Your new 35cc EXTRA 300 ARF-QB is a highly aerobatic airplane. It is capable of both pre-
cision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state
of the art CAD design, LASER cut technology, and high quality included hardware. We hope
you enjoy building and flying your 35cc EXTRA 300 ARF-QB.
Great care has been taken in both the design and manufacturing of the 35cc EXTRA 300
ARF-QB to allow for the strongest and lightest construction possible. Only the highest qual-
ity materials from the covering, paint, wood and hardware have been used in the construction
of this model.
The 35cc EXTRA 300 ARF-QB has been individually hand built, covered and painted by
trained and experienced craftsmen with over 25 years of manufacturing experience. Using
CAD design, laser cut technology and jig-built assures accuracy in all stages of production.
The 35cc EXTRA 300 ARF-QB is designed for gas engines in the 35cc to 45cc category.
The Brillelli 46cc engine is shown in the assembly instructions. The aircraft was tested with
the Brillelli 46cc and has outstanding performance. The final choice of engine is left up to
the builder. A computer radio is recommended to allow the pilot to take advantage of the full
capabilities of this aerobatic aircraft.
IMPORTANT Please read through this manual carefully, before starting the assembly of
your new 35cc EXTRA 300 ARF-QB . Inventory and inspect all parts and hardware for any
imperfections or damage. Notify Aeroworks immediately if there are missing or dam-
aged parts. INTENDED USE
This plane should not be regarded as a toy. This is an aerobatic plane and is recommended for pilots
who are beyond the trainer-stage and are comfortable with flying an aerobatic sport plane.
!READ! WARRANTY !READ!
It is important to notify Aeroworks of any damage or problems with the model within 30
days of receiving your airplane to be covered under warranty. All returned parts must be
shipped in their original shipping boxes and insured for full replacement value. If you wish to
return this aircraft for any reason a 15% restock fee will be charged to the customer. In addi-
tion the customer is responsible for all return shipping cost and all prior shipping cost will
not be refunded. Parts will be fixed or replaced once the original item is returned at the
owner’s expense. It is the decision of Aeroworks if the item is to be replaced or repaired.
Aeroworks cannot insure the skill of the modeler and can not influence the builder during the
construction or use of this aircraft, and therefore, will not be accountable for any property
damage, bodily injury or death caused by this aircraft.
Aeroworks cannot insure the skill of the modeler and can not influence the builder during the
construction or use of this aircraft, and therefore,
The purchaser/operator accepts all responsibility of any and all structural or
mechanical failures.

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KIT CONTENTS
35cc Extra 300 ARF-QB
Materials List
Basic Aircraft Parts
Fuselage with pre-installed vertical fin – covered,
Pre-installed and fuel-proofed firewall, pre drilled
for the rudder hinges and tail wheel assembly.
(4) 8-32 blind nuts installed for main landing gear
(4) 4-40 blind nuts installed for the mounting the
stab.
(6) 4-40 blind nuts installed for the mounting of
cowling.
(1) Hatch cover for the landing gear installed by (2)
T2.6 x 16mm PWA screws (2) flat washers.
(1) Canopy base—painted with (4) 4-40 blind nuts
installed
(1) Tinted Canopy—glued on the canopy base and
painted, installed on the fuselage by (4) 4-40 x 14
mm hex style bolts
(4) #6 bonded washers for the mounting of the
Canopy
(2) pull-pull exit tubes for rudder cable installed
(1) Antenna Tube installed
(1) Engine box hatch cover, installed
Left Wing with Aileron – covered: pre drilled for control
horn mounting
(2) 6-32 blind nuts installed for the wing mounting.
(2) locater pins installed, pre drilled for cotter pin
(6) pin point hinges installed and glued
(1) Aileron servo string installed
Right Wing with Aileron – covered: pre drilled for
control horn mounting
(2) 6-32 blind nuts installed for the wing mounting.
(2) locater pins glued, pre drilled for cotter pin
(6) pin point hinges installed and glued
(1) Aileron servo string installed

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Horizontal Stabilizer with elevator assembly with (8)
pin point hinges (glued)---covered, pre-drilled for control
horns.
Rudder with (5) pin point hinges (not glued) – covered,
pre-drilled for control horns.
SUB ASSEMBLIES
#1:
(1) Fiberglass Cowling—painted with (6) screw holes
(6) 4-40 x 10mm hex style bolts for mounting cowling
(6) 3mm split lock washers for mounting cowling
(6) #6 bonded washers for mounting cowling.
#2:
(1) 3mm 7075 Aluminum Main Landing Gear -- painted
(2) 4x33mm Axle Bolts
(2) M4 lock nuts
(4) 4mm i.d. Wheel Collars with set-screws
(2) 76mm Dia. Main Wheels (Lite Type)
(4) 4-40 x 10mm hex style bolts for mounting wheel
pants
(4) 3mm flat washer for mounting wheel pants
(4) 3mm split ring lock washer for mounting wheel
pants
(4) 8-32 x 20mm hex head bolts for mounting main
landing gear
(4) 4mm flat washers for mounting main landing gear
(4) 4mm split ring lock washers for mounting main
landing gear.
#3:
(2) Wheel Pants—1 Left and 1 Right---Painted
(4) 4-40 blind nuts installed on the wheel pants, 2 per
side.
(2) Gear Cuffs - pre mounted - painted. 1 left, 1 right
(4) T2x8mm bolts - cuff mounting
#4:
(1) Tail Wheel Assembly – small
#5:
(1) 23mm O.D. Composite Wing Tube
(2) 8mm O.D. Composite stab tubes
(one front and one rear).
(4) 6-32x25mm Hex head bolts for wing mounting
(4) #8 bonded washer for wing mounting
(4) 1.8mm hair pin for wing security - attachment
(4) 4-40x10mm Hex head bolts for stab mounting
(4) #6 bonded washers for stab mounting
#6:
(2) 4-40 3” two end threaded pushrod with nuts for
ailerons
(2) 4-40 4” two end threaded pushrod with nuts for
elevators.
(2) 4-40 x300mmThreaded pushrod - throttle and choke.
(2) 4-40 solder coupler - throttle and choke
(2) 4-40 metal clevis - throttle and choke
(2) 4-40 ball links - throttle and choke
#7:
(2) 0.8x1100mm plastic coated pull-pull steel cable.
(4) 3.5x5mm brass pull-pull swaging tubes
(6) AW double control horns
(36) T2.6X12mm Phillips head mounting screws
#8: (1) 750cc (25 oz) Fuel Tank assembly
(2) Fuel stopper (1 Glow, 1 Gas)
3’ large gas fuel line
(2) Brass Barbs
#9:
(2) Servo mounting plates (throttle and choke)
(2) Engine mounting template (Brillelli 46cc and
blank for universal mounting)
(1) 160x70x6mm foam for the Fuel tank.
(2) 300x80x8mm foam for the receiver and battery
(10)3x 200mm Nylon Ties
(6) 8x500mm Nylon Ties
(1) 8” x 11” paper material for cutting cowl
(6) Rubber grommets– fuel line and wire guide
#10
(12) 4-40 ball links / ailerons - elevators - rudder
(6) Brass spacers
(6) Flat washers
#11
(1) Covering - White (small patching or repair)
(1) Covering - Orange (small patching or repair)
(1) Covering - Sky Blue (small patching or repair)
(1) Covering - Silver (small patching or repair)
(1) Transparent covering - sealing hinge gaps
#12
(1) AW - Custom Rudder throw meter - measure control
Deflection
#13
(1) Assembly Manual with picture folders on CD
#14
(1) Custom Vinyl decal set

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Hardware:
ITEMS NEEDED TO COMPLETE
• 35cc to 45cc Gas engine and ignition
• Standard or Pitts style muffler (Pitts Recommended)
• 1.80 to 2.20 Glow Engine
• Engine mount, mounting bolts, lock nuts, and
flat washers.
• 3” Spinner and propeller of choice
• 2 x aileron servos (min 180 in./oz. Torque @ 6
volt, Digital, Metal Geared)
• 1 x rudder servo (min 180 in./oz. Torque @ 6
volt, Digital, Metal Geared)
• 2 x elevator servos (min 180 in./oz. Torque @ 6
volt, Digital, Metal Geared)
• 1 x throttle servo (Fast / Reliable)
• 1 x choke servo (Fast / Reliable) optional
• Servo extensions 6 x 6,” 2 x 24”
• 1 x 6 channel receiver (PCM recommended)
• 1 x receiver battery (min 6.0 volt / 1700ma)
• 1 x ignition battery (min 4.8 volt / 1700ma)
• 2 x switches with charge jacks
Tools:
• Allen wrenches US and Metric.
• Dremel cutting disc and sanding drum tool
• Electric drill and selection of bits
• Razor saw
• Flat head screwdriver
• Hobby heat gun
• Hobby iron and covering sock
• Masking tape
• Modeling knife
• Needle nose pliers or crimping tool
• Paper towels
• Pen, pencil or felt tipped marker
• Phillips screwdriver
• Rubbing alcohol
• Ruler and tape measure
• Scissors
• T pins
• Waxed paper
• Wire Cutters
Adhesives:
• 15-30 Minute epoxy
• Blue Loctite
• Epoxy mixing cups, mixing sticks, brushes
• CA kicker (optional)
• Thick, Thin and Medium CA
• Rubbing alcohol
• Wipes
WARNING
Some rubbing alcohols
may attack painted parts.

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1. Open your kit slowly and take care not to dam-
age any parts of the kit. Remove all parts from
their plastic protective covers for inspection.
Before doing any assembly or installation of any
decals it is very important to re-shrink or re-
tighten the already applied covering. Due to the
shipping process, heat and humidity changes
from different climates, the covering may be-
come lose and wrinkle in the sun. If you take the
time to re-tighten the covering, you will be re-
warded with a long lasting beautifully covered
model.
TIGHTENINGAND RE-SHRINKING THE COVERING
2. Using your covering iron with a soft sock, gently
apply pressure and rub in the covering. If any
bubbles occur, your iron may be to hot. Reduce
heat and work slowly.
3. If bubbles persist, use a small pin to punch holes
in the bubble to relieve trapped air and reheat.
4. Use your heat gun with extreme caution. Take
care not to apply too much heat to one area for
long periods of time. This may cause the trim
colors to over shrink and pull away leaving un-
sightly gaps on the color lines. The trim stripes
are especially vulnerable to over shrinking.
5. Your model is covered with Ultracote™ cover-
ing. In case of repairs, the colors are:
Sky Blue #875
Silver #881
Orange #877
White #870
Tightening and re-shrinking the covering is a
never ending process and needs to be
checked after each flying secession.

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1. Go over all seams and color overlaps with your
sealing iron.
Note: Even if your models covering has no wrin-
kles out of the box it is still very important to go
over all seams and overlaps to make certain they are
sealed securely. This is especially important at the
leading edges of the wings and stabs. We recom-
mend checking the covering after each flying ses-
sion.
CHECKING SEAMS AND COLOR OVERLAPS FOR GOOD SEAL
2. Use your covering iron to ensure all edges,
seams, and color overlaps are securely sealed.
3. This is an optional step but is recommended.
Cut strips of clear covering to fit the hinge
gaps. Use covering iron to seal the clear
covering snugly into the bottom of the
hinge lines as shown for air tight hinge
seals.
IMPORTANT:
It is the users responsibility to check the
covering seams and overlaps for security and a
good seal. Aeroworks is not responsible for
failure of covering seams or overlaps during
flight.
This is a never ending process that must
be done after each flying secession. Due to
varying temperatures and humidity changes
from day to day the covering will continue to
loosen and must be maintained.

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Aileron Servo Installation
1. The ailerons have been pre-hinged and glued to
the wing panels and are ready for flight. No
other steps are necessary for hinging.
Gather one wing panel, one aileron servo, and
one 6” servo extension as shown below for servo
installation.
WINGASSEMBLY
2. Layout the servo on the wing to test fit the in-
stallation and ensure servo lead is the correct
length.
Note: 180 in. oz. digital, metal geared servos are
recommended. Servo selection can be the difference
between a great flying model and a model that will
crash. Always use brand name high quality servos.
3. Attach the 6” extension to the servo lead and
secure with safety wire, string, tape, or other
method. Ensure the plugs will not come apart
from vibration or light tension.
4. Fasten the pull string from the servo hole to the
male plug of the servo extension.
Safety Clips
Available
from
Aeroworks

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5. Draw the 6” servo extension through the wing
and pull through the wing root rib.
6. Install servo in servo well with the output arm
toward the leading edge of the wing. Mark and
drill location of servo mounting holes.
7. Install servo with servo mounting screws.
Pushrod / Control Horn Installation
1. Gather the aileron control linkage parts as shown
below. 1 pushrod, 2 ball link assemblies, 1 brass
spacer, 1 Flat washer, 1 left and 1 right side con-
trol horn, and 6 2.6 x 12mm wood screws for
each wing panel.

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2. Assemble the pushrod and control horn assem-
bly as shown. The ball link goes between the
left and right sides of the control horn sides and
is secured with a nylon lock nut. Start with the
center hole in the control horn. The ball link
may be moved up or down for more or less con-
trol throw. Brass spacer goes between servo arm
and ball link
3. Correct installation of ball link to servo arm
shown below.
Note: Flat washer will prevent ball link from
coming loose from brass ball.
4. Place the control horns over the predrilled
mounting holes.
5. Use a drop of thick CA glue on each screw to
prevent screws from loosening due to vibration
as shown.

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6. Securely fasten the control horn to the aileron
with six wood screws as shown.
7. Tape the trailing edge of the aileron to the trail-
ing edge of the wing in the neutral position.
Plug the servo into the receiver and turn radio
on. Ensure the servo trim and sub trim is cen-
tered. Adjust the length of the pushrod so that
the servo arm is parallel to the aileron hinge line
when it is placed on the servo output shaft.
Screw servo arm on the servo output shaft.
Note: On metal geared servos use Blue Loctite for
all Servo arm mounting screws.
8. Ensure the servo does not bind at either end
point at full deflection. A 1” servo arm is rec-
ommended for best results. A 1 1/4” servo arm
is required for full deflection of the aileron 55º
bevel.
9. Repeat all the above steps for the other wing.

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Elevator Servo Installation
1. The elevators have been pre-hinged and glued to
the stabs and are ready for flight. No other steps
are necessary for hinging.
Note: Use clear covering for sealing the hinge
gaps. This is an optional step but is
recommended
Gather the stab and elevator, elevator servo, and
24” servo extension as shown below.
STAB AND ELEVATOR ASSEMBLY
2. Attach the 24” extension to the servo lead and
secure with safety wire, string, tape, or other
method. Ensure the plugs will not come apart
from vibration or light tension.
Note: 180 in. oz. digital, metal geared servos are
recommended. Servo selection can be the differ-
ence between a great flying model and a model
that will crash. Always use brand name high
quality servos.
3. Layout the servo on the fuse to test fit the instal-
lation and ensure servo lead is the correct length.
4. Feed servo extension through the elevator servo
mounting hole in fuse. Place servo into mount-
ing hole in fuse with servo output shaft facing
toward the rear as shown. Mark and drill loca-
tion of servo mounting holes.
Safety Clips
Available
from
Aeroworks

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5. Install servo with servo mounting screws.
Pushrod / Control Horn Installation
1. Gather the elevator control linkage parts as
shown below. 1 pushrod, 2 ball link assemblies,
1 brass spacer, 1 flat washer, 1 left and 1 right
side control horn, and 6 2.6 x 12mm wood
screws for each wing panel.
2. Assemble the pushrod and control horn assem-
bly as shown. The ball link goes between the
left and right sides of the control horn sides and
is secured with a nylon lock nut. Start with the
center hole in the control horn. The ball link
may be moved up or down for more or less con-
trol throw. Brass spacer goes between servo arm
and ball link
3. Correct installation of ball link to servo arm
shown below.
Note: Flat washer will prevent ball link from
coming loose from brass ball.

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4. Place the control horns over the predrilled
mounting holes.
5. Use a drop of thick CA glue on each screw to
prevent screws from loosening due to vibration
as shown.
6. Mount the control horn using six wood screws.
7. Correct installation of elevator servo linkage to
elevator control horn shown below.

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8. Tape leading edge of the elevator balance tab to
the leading edge of the stab in the neutral posi-
tion. Plug the elevator servo into the receiver
and turn radio on. Ensure the servo trim is cen-
tered.
9. Attach the stab and elevator to the fuse and bolt
in place. Adjust the length of the elevator push-
rod so that the servo arm is 90 degrees to the
servo case when it is placed on the servo output
shaft. Ensure the servo does not bind at either
end point at full deflection.
10. Repeat the above steps for the other stab and
elevator.
11. Finished elevator servo installation shown be-
low.

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Rudder Installation
1. Gather the rudder, five hinges, rubbing alcohol,
petroleum jelly and epoxy materials as shown.
Use 15-30 minute epoxy to ensure adequate
working and cleanup time.
RUDDER AND PULL – PULL CABLE ASSEMBLY
2. Prep all hinges for installation by applying Vase-
line petroleum jelly or light oil to the hinge joint.
This ensures no epoxy gets into the hinge during
assembly.
3. Mix epoxy in mixing cup and use a tapered stick
to apply the epoxy inside the pre-drilled holes in
the trailing edge of the fin. Apply epoxy to one
side of each hinge and insert the hinge com-
pletely into the hole. Ensure the hinge axis is
vertical and parallel to the trailing edge of the fin
before epoxy cures. Wipe away excess epoxy
with alcohol wetted wipes.
4. Epoxy the hinges into the fin first and allow ep-
oxy to fully cure.

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5. Mix epoxy in mixing cup and use a tapered stick
to apply the epoxy inside the pre-drilled holes in
the leading edge of the rudder. Apply epoxy to
trailing edge of each hinge.
6. Carefully slide the rudder onto each hinge and
against the trailing edge of the fin. Wipe away
excess epoxy with alcohol wetted wipes.
7. Ensure there is no gap between fin and rudder.
Allow epoxy to fully cure.
Note: Use clear covering for sealing the hinge
gaps. This is an optional step but is
recommended
Rudder Horn, Pull-Pull Cable and
Servo Installation
1. Gather the rudder control linkage parts shown
below. 2 rudder cables, 4 ball link assemblies, 2
flat washers, 4 threaded couplers, 4 brass swag-
ing tubes, 2 left and 2 right side control horns,
and 12 2.6 x 12mm wood screws.

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2. Gather the rudder control horn parts as shown
below. 2 ball link assemblies, 2 left and 2 right
side control horns. Assemble the ball links be-
tween the control horns as shown. Secure with
nylon lock nut. Start with the center hole in the
control horn. The ball link may be moved up or
down for more or less control throw.
3. Thread brass coupler half way into ball link.
4. Place the control horns over the predrilled
mounting holes.
5. Use a drop of thick CA glue on each screw as
shown.