AirfoilZ Extra 260 User manual

Extra 260
Assembly Manual
Specifications
Wing Span: 40 inches
Wing Area: 350 in2
Fuselage Length: 35.5 inches
Weight ready to fly): 19 to 23 oz.
Wing Loading: 7.8 to 9.5 oz/ft2
Designed by Jim Vigani
Ve sion 1.0 – 11/9/07

A Tech Hobbies,LLC Company
PO box 301
Edison, New Je sey 08817
Ph: [phone]
Fax: [phone]
Website: www.ai foilz.com
e-mail: info@ai foilz.com
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Limited Warranty
Ai foilZ takes p ide in the ca e and attention given to the manufactu e of the components in this
kit. The company wa ants eplacement of any mate ials found to be defective fo thei intended
use p io to thei use in the const uction of the model, p ovided the pu chase equests such
eplacement within a one yea pe iod f om the date of pu chase, and the pa t is etu ned, if so
equested by the Company. No othe wa anty, exp essed o implied, is made by the company
with espect to this kit. The pu chase assumes full esponsibility fo the isk and all liability fo
pe sonal o p ope ty damage o inju y esulting f om the pu chase ’s use of the components of
this kit whethe assembled o not.
The Company ese ves the ight to p ovide a full efund to the pu chase if the model does not
pe fo m as adve tised. Any efund is at the sole disc etion of the Company.
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Introduction:
Thank you fo choosing the Ext a 260 ai plane. We have taken g eat ca e to p ovide a design and
kit components that, when p ope ly assembled, will give you a high quality model with outstanding
pe fo mance. While the assembly is not complicated, the quality and ultimate pe fo mance of you
model will depend on the ca e you take while building. Please read these instructions carefully
and be sure that you understand them before you start. Take ca e to assemble the components
as shown and in p ope alignment. Please note that some of the parts shown may be different
in material from those provided in the kit. The installation of these parts is unaffected by the
material change.
Warning
This radio-controlled model is not a toy and, if operated inappropriately can cause serious
bodily injury and property damage. It is the buyer’s responsibility to assemble the kit correctly
and properly install the motor, radio and all other equipment. The model must always be flown in
accordance with the safety standards of the Academy of Model Aeronautics (AMA).
This model is desi ned for hi h performance. While it is reasonably simple to assemble, it is not
intended for the novice flier. Do not attempt to learn to fly with this model! If you are an
inexperienced modeler, we recommend that you et the assistance of an experienced modeler to
help you with the assembly and initial fli hts. There are many local clubs that can offer help with
assembly and fli ht instruction. Information on local clubs can be found throu h the Academy of
Model Aeronautics. The AMA has over 2500 chartered clubs throu hout the country. Information
on the AMA can be found at www.modelaircraft.or .
We do not recommend the use of hot lue for mountin components such as servos, control horns,
receivers or speed controls.
Recommended Power System:
This plane has been designed to use a 150 to 250 watt powe system. Recommended moto s
include the Hacke A20-20L, Sco pion 2215-18, o AXI 2217-16 with a 20 to 25 amp speed
cont olle , and a 1320 to 2100 mAh, 3S Li-poly batte y with a 10x4.7 o 10x5 p opelle . Othe powe
systems with simila capabilities can be used. Pe fo mance will va y depending on the specific
powe system selected. Fo info mation on alte nate powe systems please visit
http://3dxhobbies.com o you local hobby shop.
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Kit Contents:
Befo e you sta t the assembly of this model, check to make su e that the e a e no missing pa ts and
that none of the pa ts have been damaged du ing shipment. If you have any questions with the
assembly o flying of this model, please contact us and we will be happy to assist you. If you need
eplacement pa ts please p ovide the model name. The pa ts included in the kit a e shown on the
Pa t Sheet included with the kit.
Other items you may need that are not included with your kit:
Building Supplies:
In addition to the kit contents, we ecommend having the following building supplies on hand to
complete the kit assembly in acco dance with this manual.
Foam safe (odo less) CA
Foam safe CA “Kicke ”
Thin CA
Go illa glue
5 and 15 minute epoxy
Double back tape o sp ay adhesive
Low tack masking tape (blue painte ’s tape)
Sanding block with 100 g it sandpape
Sanding stick o eme y boa d (150 g it)
Solde ing i on and esin co e solde
1/32 inch and 1/16 inch diamete d ill bits
Exacto knife with #11 blade
Utility knife
Small squa e
36 inch ule
Needle nose plie s
3/8 inch diamete b ass tubing
Diagonal cutting plie s
Power and Control Equipment:
The following items a e needed to p ovide powe and cont ol function to you model.
B ushless out unne moto with adial mount
4 moto mounting sc ews
B ushless moto speed cont ol
4 mic o se vos (Hitec HS55 o equivalent)
3S Li-poly batte y pack
LI-poly batte y cha ge
4 o 6 channel mic o eceive
Y ha ness if a 4 channel eceive is used
3 to 6 channel t ansmitte
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Making a Sanding Block:
The leading edges of the elevato , the udde , and both aile ons need to be beveled p io to
installing the hinges. This is best pe fo med by the use of a 2-inch wide by 12 inch long, 100 o 120
g it sanding block o sanding ba . In addition, othe a eas of the ai f ame need to be sanded as
shown in this manual to complete the assembly and enhance appea ance. If you do not have a
suitable sanding block, one can be easily made by secu ing a piece of 100 g it sand pape to a 2
inch x 12 inch x ¾ inch wooden block. The sandpape can be secu ed to the block using eithe
double backed tape o sp ay adhesive. ake sure that the block is flat! A sty ofoam block is
g eat fo gene al sanding of the fuselage and non-beveled edges of the cont ol su faces.
Figure: Figure:
Figure:
General Comments on Assembly:
While not difficult to assemble, the Ext a 260 kit is intended fo pe sons with some building
expe ience. As such, the inst uctions a e p esented as a simple sequence that, when followed, will
help ensu e that the ai f ame tu ns out st aight and light. Imp ope ly aligned su faces and
unnecessa y weight will only hinde its pe fo mance. Apply glue and epoxy in a thin unifo m coat,
using only enough to achieve a st ong bond. Excess glue o epoxy will only add unnecessa y
weight and will not inc ease the st ength of you model. T ial fit all components to ensu e fit and
alignment befo e applying any glue o epoxy. Keeping joints tight fitting will minimize the amount of
glue equi ed and will ensu e a st ong bond. When gluing foam to foam, or foam to wood, use
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only foam safe CA and foam safe kicker. The e a e two basic methods that can be used when
gluing flat pieces of foam togethe such as when gluing the foam double s to the fuselage skin. The
fi st method involves applying CA to the smalle pa t, positioning it in place and then sp aying a light
sp ay of foam safe kicke along the pe imete of the pa t. The second method involves applying CA
to the smalle pa t, and lightly sp aying the mating pa t with foam safe kicke . The pa ts a e then
joined.
Use a light touch while sanding. Foam cuts ve y quickly and excess p essu e can limit you ability to
accu ately shape the foam. Take ext a ca e not to ove sand. Avoid sc atching the su face of the
Dep on foam.
Graphics:
The Ext a 260 comes with p inted vinyl g aphics. Ext a ca e in cutting out and applying the vinyl
panels will esult in a painted look fo you plane. Some people p efe to lightly mist the su face with
“F eb eze” befo e applying the vinyl. This allows the vinyl to be epositioned while applying them.
Fuselage Assembly:
The fuselage assembly on the Ext a 260 consists of a plywood and foam c utch assembly cove ed
with a dep on skin.
Fuse Assembly
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Skin Assembly
Skin Component Pa ts
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C utch Assembly
Follow the steps in the order outlined below to ensure accurate alignment of the
components.
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Step 1
Glue the wing root doubler
in place with foam safe CA
being careful to ensure the
wing openings are in
perfect alignment. Tip:
Before joining, apply CA to
the doubler and lightly
spray kicker on the fuse
skin.
Step 2
Using the plywood nose
doubler as a guide, glue
the top front doubler in
place with foam safe CA.
DO NOT GLUE THE
PLYWOOD NOSE
DOUBLER IN PLACE!
NOTE: The top front
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
help ensure proper
alignment.
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Step 3
Glue the lower rear doubler
in place with foam safe CA.
NOTE: The lower rear
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
ensure proper alignment.
Step 4
Glue the upper rear
doubler in place with foam
safe CA.
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Align the tab on the upper
rear double flush with the
skin surface.
Step 5
Glue the stab support in
place with foam safe CA.
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Step 6
Trim off the top front
doubler alignment tab flush
with the upper rear
doubler.
Repeat Steps 1 to 3 for the other skin assembly making sure to make a
LEFT and a RIGHT side version!
Step 7
Dry assemble all the
plywood crutch pieces and
check for fit. The pieces
should snap together and
self align. If the fit is tight,
lightly sand the notches for
a snug fit.
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Step 8
Glue the plywood crutch
parts and landing gear
mount parts together with
medium CA. Insert foam
formers and glue in place
with medium foam safe CA.
TIP: tack glue the plywood
pieces in place with thin CA
then re-glue with medium
CA.
Landing Gear Mount
Assembly
Glue the plywood landing
gear mount in place with
medium CA.
Glue the landing gear wire
support in place with
medium CA making sure
that the holes in the landing
gear mount align with the
opening in the landing gear
wire support.
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Glue the landing gear wire
torsion support in place
with medium CA making
sure the slot in the support
aligns with the hole in the
landing gear mount. TIP:
Insert a piece of 3/32 wire
into the hole and use as an
alignment guide.
Glue the landing gear wire
torsion support cap in place
with medium CA. Repeat
for the other side.
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Glue the crutch bottom
support in place with
medium CA.
Step 9
Test fit the rudder servo in
the crutch. Trim the
opening as necessary to
match the servo.
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Step 10
Test fit the skins on the
crutch and check that the
slot in the rear of the skin
mates with the alignment
tab on the rear of the
crutch.
Step 11
Glue the crutch to one skin
assembly from the nose to
just behind the wing
opening with medium foam
safe CA. After the glue has
set, glue the skin to the
lower crutch member from
the wing opening to the rear
tab, making sure the rear
alignment tab is properly
seated in the slot. Make
sure the rear of the upper
crutch does not interfere
with the slot for the
horizontal stabilizer.
Repeat Steps 10 and 11 for the other skin.
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Step 12
Glue the top rear edges
of the fuselage together
with medium foam safe
CA .
Step 13
Test fit the canopy filler
piece and glue in place
with medium foam safe
CA.
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Step 14
Glue the front deck in
position with medium foam
safe CA.
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Step 15
Glue the top cowl skin in
place with medium foam
safe CA. Tip: Before gluing,
lightly score the backside of
the top skin with an old
ballpoint pen to allow the
foam to be bent around the
nose without cracking. Pre-
bend the foam before gluing
in place.
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Step 16
Trim the front of the top
cowl piece and glue in a
3/8” wide scrap piece of 3
mm foam for support with
foam safe CA.
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