AJ Aircraft 73 Laser 230z User manual

73” AJ Laser 230z
Assembly Instructions

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Congratulations
Whether you're looking to go out and go 3d huckin' or lay down a smooth-as-butter precision flight, the 73"
Laser 230z is for you! The wings have been thoroughly refined to allow precision flying, while not sacrificing
any 3d characteristics. With a generous fuselage height, the model flies as well on its side as it does upright.
Generously sized control surfaces give you excellent authority at all speeds. The Laser 230z features an
awesomely light but strong airframe and a light wing loading that will handle anything you want it to.
Building the airplane is very straight forward. The rudder cables are pre-installed, hinges are pre-installed and
blind nuts in the wing tips for the included SFG's make it easy to get this bird in the air in no time flat.
Transporting this big bird is no problem with the now included removable rudder. We've also added an
additional hard-point in the rudder for push-pull setups.
Can't decide which power system to add to your 73" Laser? The electric setup gives the ability to strap
batteries (8-12s) in and just go fly. You can expect around 6-7 minute flight times with great power and ultra-
reliability. Love the smell of burning gas in the morning? We've successfully tested the laser 230z with the
DA-35 and the Valley View 40cc twin. With a 16oz Fortitude tank you will see flight times approaching 15
minutes! When using the Valley View twin, it is recommended to add a second elevator servo for balance.
AJs' personal pick for this 73" Laser 230z is the 8s electric setup, ultra-floaty and a great flight envelope.
Whichever you choose, we're sure it'll put a smile on your face every time you fly it!
Up Your Game! Fly AJ
AJ Aircraft thanks you for the purchase of this airplane. Top grade materials and precision assembly has gone
into this to make this a top quality aircraft. Following the directions closely, will assure you many hours of
thrilling flight. Two years of design, development and testing has gone into this airframe. We hope you’re as
happy with it as we are!
Features
Specs:
Wing Span - 73"
Length - 70"
AUW - 10-11 lb
Power(Elec) - 2500+ Watt motor, 120Amp
or 100Amp ESC, 8s 4400mah LiPo
Power(Gas) - 30-40cc
Radio - 5 channel with 4 high torque
servos
What's in the box:
73” Laser 230 Airframe
Fiberglass Cowl & Wheel Pants
Carbon Fiber Main Gear
Pre-Hinged Control Surfaces
Removable Rudder
G-10 Control Horns
Dual Ball Links for all Connections
Carbon Fiber Wing Tube
Optional Side Force Generators (SFG)
Genuine Ultracote Covering
Wing Bags
Muffler Canister Mounts

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WARNING!
AJ Aircraft’s extensive testing ensures a high quality kit that has gone through many stages to
provide you with a safe, reliable, airframe. Poor assembly will lead to an unsafe model and
therefore the instructions must be followed closely. Should you have any questions, please do
not hesitate to contact us. The safe operation of this model is your responsibility and yours
alone. If you are a beginner or have never flown a model of this size and power you should
attempt it with the help of an experienced pilot. This product should not be considered a toy,
but rather a sophisticated, working model that functions much like a full-scale airplane.
Because of its performance capabilities, this product, if not assembled and operated correctly,
could cause injury to you or spectators and damage to property.

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Contents
Congratulations....................................................................................................................................................................... 1
Features .................................................................................................................................................................................. 1
Optional Configurations.......................................................................................................................................................... 4
Recommended Items for Completion..................................................................................................................................... 4
Tools........................................................................................................................................................................................ 5
Covering .................................................................................................................................................................................. 6
Wings ...................................................................................................................................................................................... 6
Landing Gear .........................................................................................................................................................................11
Wheel Pants ..........................................................................................................................................................................12
Fuselage ................................................................................................................................................................................14
Elevator .................................................................................................................................................................................16
Rudder...................................................................................................................................................................................21
Push-Pull Rudder Control..................................................................................................................................................21
Pull-Pull Rudder Control....................................................................................................................................................22
Electric Motor .......................................................................................................................................................................25
Gas Engine.............................................................................................................................................................................27
Cowl & Canopy......................................................................................................................................................................30
Radio Installation & Setup ....................................................................................................................................................32
Before starting, read through the entire set of instructions to familiarize yourself with the
process.
If there’s ever a question, contact AJ Aircraft.
Inspect the packing material carefully for the rudder hinge pin.

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Optional Configurations
This model is designed for a gasoline engine or an electric motor. Fastener, servo hardware, and electric motor box are
provided for optional setups. You also have the option of using 1 or 2 elevator servos and a pull-pull rudder servo or 1
elevator servo and a push-pull rudder servo setup.
Recommended Items for Completion
Power System
oElectric Motor (If you choose to go electric.)
Hacker A60-5S or Equivalent
Castle Ice 100 Amp or Equivalent
12” ESC (Servo) Wire Extensions
8s Battery
Prop suited for the motor you choose. (21x10, …)
3” (76mm) Spinner
oGas Engine (If you choose to go gasoline.)
DA-35 or Equivalent 35cc
Standard sized metal geared throttle servo.
Ignition Shut Off
Ignition/Receiver Battery
16 oz Gasoline Safe Fuel Tank
Gasoline Safe Fuel Line
Fuel Dot
Fuel Filter
2x 12” Servo Wire Extensions
Prop suited for the engine you choose. (20x8, 20x9…)
3” (76mm) Spinner
Aileron Servos
o2x 250 oz/in Metal Geared, (Hitec HS-7955TG Recommended)
o2x 12” Servo Wire Extensions (in wings)
o2x 6” Servo Wire Extensions (to receiver)
o2x 1.25” Servo Arm for 3D Aerobatics (Or a heavy duty servo arms for sport flying.)
AJ flies this airframe with
the following equipment:
Hacker A60-5s
Falcon 21x10 prop
Jetti Mezon 120 or
Castle Ice 100 ESC
2x Thunder Power 4s 4400mah
G8 Performance Pro 45C
Castle Pro BEC
Thunder Power 2s 2100mah G8
Pro-lite + 25C
Futaba 9157 servos on
Elevator/Rudder
Futaba 9452 servos on Ailerons

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Rudder Servo
oThis model can be configured with a pull-pull cable rudder servo or using a push-pull servo mounted in the
tail.
o1x 250 oz/in Metal Geared, (Hitec HS-7955TG Recommended)
2.5” Double Servo Arm for a Pull-Pull cable setup.
1.5” Servo Arm for a Push-Pull setup. (Or a heavy duty servo arms for sport flying.)
24” Servo Wire Extension for a Push-Pull setup.
Elevator Servo
oThis model can be configured with 1 or 2 elevator servos.
(You must use a pull-pull rudder setup if you plan to use 2 elevator servos.)
o250 oz/in Metal Geared, (Hitec HS-7955TG Recommended)
o1.5” Servo Arm for 3D Aerobatics (Or a heavy duty servo arms for sport flying.)
o24” servo wire extensions (1 or 2)
Radio System
o5 or 6 channel full range radio system
oPower Switch
oReceiver Battery
oVibration padding for receiver and receiver battery.
Tools
Blue Painters Masking Tape
Thin CA Glue
30 Minute Epoxy
Polyurethane Glue (Gorilla Glue)
Denatured Alcohol
Paper Towels
Removable Thread Locker (Loctite 242, Blue)
Metric & SAE (fractional) Allen Wrenches
Hobby Knife & Fresh Blades
Covering Iron (Trim Iron)
Small Flat File
Small Round File
Electric Drill w/ Assorted Small Bits
Small Flat Blade Screwdrivers
Small Phillips Screwdriver
Sandpaper (150-220 Grit)
Needle Nose Pliers
Crimping Plyers
Measuring Tape & Ruler

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Covering
The covering on your Laser may have developed loose areas through temperature and humidity changes between
manufacturing and shipping. This may also occur during the summer heat. The covering may require retightening a few
times during your first summer of flying.
Take a few minutes to go over all of the seams making sure all edges are secure. Then proceed to shrinking any area
that may need tightening. (Using an iron sock will reduce scratches.)
Wings
The ailerons are pre hinged and glued to the wing. Firmly
tug at each hinge point to ensure hinges are installed
properly. It’s better to find a loose hinge now rather than
during a flight.
Carefully locate the aileron servo
pocket. (Shining a light through
opposite side of the wing will help
highlight the pocket location.) Use
a new hobby knife blade to cut
though the covering. Cut from the
corners of the pocket towards the
center of the pocket so the
covering can be folded in.
Gently snap off the servo wire installation string and
temporarily secure it out of the way. Do not pull it out of
the wing.
Use a trim iron to seal the bottom surface of the wing
around the servo pocket. Fold the cut covering under the
wing sheeting and attach it to the inside edge of the
pocket.
At 200-220°F (93-104°C) the adhesive on UltraCote® becomes active
allowing the covering to be attached to the model. While 220° will fully
bond the covering to the model it is well below the temperature that
causes UltraCote® to shrink.
At 300°F (149°C) the initial shrinking of UltraCote® begins.
At 350°F (176°C) UltraCote® reaches its maximum shrinking point. Raising
the temperature above this point will not cause further shrinkage.
Use as little heat as needed. Using too much heat may cause reshrinking
issues later.
Pro Tip - If the iron you're using does not display the actual temperature,
here is a tip that will ensure your iron is properly set.Water boils at 212°F.
Allow your iron to warm up at a medium setting. When the iron reaches its
stabilized temperature, carefully pour a few drops of water on the iron's
surface. Adjust the temperature until the water just begins to boil off. This
method is surprisingly accurate and is generally within 10° (of the exact
application temperature of 220).

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Carefully locate the aileron control horn slots. Use a
covering sealing iron to bond the covering in the area the
control horn will sit. Trim the covering away to expose
the slots. Be careful you don’t cut through to the top side
covering.
Use the control horns from the “Wings” part bag.
Test fit the control horn halves in the slot first
individually, then as an assembly. The fit should be snug.
Check the alignment of the control horn to the hinge
center line. The linkage hole in the control horn should
be aligned with the hinge centerline.
With the control horn in position apply painter’s masking
tape around the control horn base. Put the tape up to
the base edge. Not under or over it.
Assemble a rod end to the control horn using a supplied
machine screw and nylon lock nut. Assembling the ball
link to the control horn at this step will help keep the
control horn halves parallel during installation later.

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Remove the control horn leaving the tape in position.
Using a new hobby knife blade and lightly cut through the
covering but not into the balsa sheeting.
Cut inside the tape edge about 1/16”.
Use sand paper to roughen the lower portion of the
control horns on both sides. Roughen one side of the
base plate. This will help the epoxy bond to the control
horn parts.
Apply epoxy to the slots in the aileron. Use a pin to help
push some epoxy in.
Apply epoxy to the control horn assembly and insert it
into the aileron slots.
Wipe away excess epoxy using a paper towel soaked with
denatured alcohol. Use an upward rolling motion as you
wipe the excess epoxy to lift it from the surface. This
helps reduce smearing the epoxy.
Check the alignment along the hinge line as you did when
you test fit the control horn. Reposition as needed.
Allow the epoxy to partially cure. Peel away the masking
tape after the epoxy is securely holding the control horn
in place and still soft enough to easily remove the tape.
Set the wing aside and let the epoxy fully cure.

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Connect the servo to a receiver and power supply. Turn
on you transmitter. Set trim and sub trim to zero. Install
a servo arm on the servo approximately perpendicular to
the servo side. Use the transmitter’s sub trim to make it
perpendicular.
Attach the servo wire to the installation string and gently
pull the wire through the wing as you insert the servo
into the wing. (Depending on the length of the servo wire
provided it may be necessary to install a servo extension
wire before installing through the wing.)
Secure wire extensions to servo leads using shrink wrap
or a safety clip.
Pre-drill for the servo mounting screws using a 1/16” drill
bit. Install the servo with the wood screws that came
with your servos. Remove the screws and servo. Apply a
drop of thin CA glue into each mounting screw hole. This
will harden the wood around the screws and provide a
more secure installation. (Allow the CA glue to dry before
reinstalling the servo.)
Reinstall the servo. Assemble a connecting rod and ball
link and to aileron ball link. Check the length of the
assembly to the servo arm with the aileron edge aligned
with the wing. Once the correct length of the assembly is
found connect it to the servo arm using the provided
machine screws washer and lock nut. (Turn on the
transmitter, receiver and servo while making adjusting to
the connecting rod. This will keep the servo in its correct
position.)

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Remove the side force generators and spacer plates from
the wing bag. Carefully locate the 2 mounting holes in
each part and trim away the covering.
The wing tips have a blind nut installed beneath the
covering. Use a hobby knife to trim away the covering.
(Use the holes in a spacer plate to help locate the holes in
the wing tip.) Assemble the spacer plate and the side
force generator to the wing with the supplied screws and
washers.

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Landing Gear
Use the landing gear fasteners located on the bottom of
the fuselage along with 3 flat washers located in the
landing gear package to assemble the landing gear. Add a
drop of removable thread locker to the screws during
assembly.
Place the wood filler block over the landing gear. Pay
attention to the fit as it is directional. We suggest using a
piece of white covering or clear packing tape to hold the
filler block in position.
Install the landing gear cuffs with the holes towards the
bottom of the airplane. Use a flat blade screw driver with
a gentle twist to help slide the cuff over the landing gear.
Secure the cuffs using 4 Phillips head screws from the
landing gear hardware package.
You may also choose to use a silicon adhesive (RTV) to
secure the cuffs in position. Apply a bead of adhesive just
above the mounting holes and slide the cuff over the
adhesive.

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Ensure all set screws are tight on the pre-assembled tail
wheel assembly.
Use the landing gear fasteners locate on the bottom of
the fuselage along with 2 flat washers located in the
landing gear package to mount the carbon fiber landing
gear. Add a drop to removable thread locker to screws
during assembly.
Wheel Pants
(You might want to install the wheels and wheel pants
last when assembling you airplane. They may get in the
way while handling during other assembly steps.)
There are 6 blind nuts provided and 6 blind nuts used in
this kit. Notice that there are 2 different sizes! Take the
time to match up blind nuts to machine screws before
proceeding to ensure you do not get them mixed up.
Two blind nuts will be used on the canopy and 4 blind
nuts will be used on the wheel pants.
File a flat on the wheel axel for the wheel collar set screw.
(Making it perpendicular to the wrench flats may help
during installation and tightening later.)
Temporarily clamp the wheel pants in position.

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Drill through the holes in the landing gear and through to
the inside of the wheel pant.
Use a machine screw and washer to draw a blind nut into
the wheel pant.
Slide the wheel onto the axel. Add the wheel collar and
tighten the set screw. Ensure it rotates freely.
Put the wheel and axel into the wheel pant then put the
axel threads through the landing gear.
Get the wheel pant mounting screws started but don’t
fully tighten.
Add the nylon locknut to the axel and tighten. Make sure
you can still get to the wheel collar set screw.
Finish by tightening the wheel pant mounting screws.

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Fuselage
Inspect for any interior joints that may have loosened as
a result of shipping & handling. Apply thin CA glue as
needed. Apply thin CA glue around the joints of the
fuselage core and rudder servo tray.
Carefully locate the mounting holes for the wing and trim
away the covering. There will be 2 holes for wing
alignment pins, 1 hole for the wing bolt, and a slot to pass
the servo wire through. Shine a flashlight through the
fuselage to highlight the holes if you have trouble
locating them.
Carefully locate the horizontal stabilizer pocket. Use a
trim iron to seal the covering around the edges of the
pocket before trimming. Use a new hobby knife blade to
cut though the covering.

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Review the servo configurations as described on page 4
before cutting the covering over the servo pockets.
Below the horizontal stabilizer slot there are 2 servo
pockets on both sides of the fuselage. The lower servo
pocket highlighted by blue painter’s tape will not be used.
The servo pocket which has the covering cut will be filled
by an elevator servo. Use a sealing iron to attach the
covering and fold it into the pocket.
The servo pockets on the opposite side are both optional.
The lower servo pocket closer to the tail of the airplane
will be used if a rudder push-pull configuration if used.
The other servo pocket will be used if a second elevator
servo is used.
Slide the horizontal stabilizer through the fuselage
pushing it all the way forward. Center it side to side using
a tape measure.
Install and center the main wing tube. Look at the plane
from the back forward to make sure that the horizontal
stabilizer is parallel with the wing tube. Notice that the
horizontal stabilizer is tapered which may obscure the
actual alignment. If the stabilizer is not aligned use shims
or sand inside the pocket until it’s parallel.
Push the horizontal stabilizer all the way forward in the
pocket. Position the stabilizer parallel to the main wing
tube. Adjust the stabilizer until the measurements to the
wing tube are equal on both sides. Continue checking the
stabilizer to ensure it is still centered as described above.
Extra time spent here will go a long way to improve the
flight characteristics of your airplane.
Once the horizontal stabilizer is positioned glue it in place
with thin CA glue. Wick glue in on both sides, top and
bottom. The use of an applicator tip is suggested to
control the flow of thin CA and get it exactly where you
want it.

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Elevator
The hardware provided may be used to control elevator
halves with 1 or 2 servos. Or the hardware can be used
with 1 elevator servo and 1 rudder servo in a push-pull
configuration.
Before you cut any covering on the elevator make sure
you have the correct half. If you cut open the servo
pocket in the left of the fuselage make sure you are
working with the left elevator.
Install the elevator control horn using the same process
as you did when assembling the ailerons.
Use a covering sealing iron to bond the covering in the
area the control horn will sit. Trim the covering away to
expose the slots.
Test fit the control horn halves in the slot individually,
then as an assembly. The fit should be snug.
Check the alignment of the control horn to the hinge
center line as you did with the wing. The linkage hole in
the control horn should be aligned with the hinge
centerline.
With the control horn in position apply painter’s masking
tape around the control horn base. Put the tape up to
the base edge. Not under or over it.
Assemble a rod end to the control horn using a supplied
machine screw and nylon lock nut. (Assembling the ball
link to the control horn at this step will help keep the
control horn halves parallel during installation.)

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Remove the control horn leaving the tape in position.
Using a new hobby knife blade lightly cut through the
covering but not into the balsa sheeting. Cut inside the
tape edge about 1/16”.
Use sand paper to roughen the lower portion of the
control horns on both sides. Roughen one side of the
base plate. This will help the epoxy bond to the control
horn parts.
Apply epoxy to the slots in the elevator. Use a pin to help
push some epoxy into the slots.
Apply epoxy to the control horn assembly and insert it
into the elevator slots.
Wipe away excess epoxy using a paper towel soaked with
denatured alcohol. Use an upward rolling motion as you
wipe the excess epoxy to lift it from the surface. This
helps reduce smearing the epoxy.
Check the alignment along the hinge line as you did when
you test fit the control horn. Reposition as needed. Allow
the epoxy to partially cure. Peel away the masking tape
after the epoxy is securely holding the control horn in
place and still soft enough to easily remove the tape. Set
aside and let the epoxy fully cure. (Repeat on second
elevator half if you will be using 2 elevator servos.)
Roughen up the jointer plate for the elevator halves with
a piece of sand paper so the epoxy will adhere better.
(The joiner plate is not used if you plan to use 2 elevator
servos. Steps related to the jointer plate can be skipped)
Test fit the elevator joiner plate to each elevator half.
Insert the joiner plate into both halves and look down the
hinge line. It should be straight. If not use a small file
and adjust the slots a little at a time. (Do not glue it yet.)

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Insert hinge pins into the elevator halves and the
horizontal stabilizer. Check the fit and gap at the hinge
line. You may need to adjust the hinge holes to minimize
the gap.
A small round file can be used to give the hinges some
clearance. Cleaning out the holes will also help you close
up any gap. Turn a 1/8” drill into the holes by hand.
Test fit pieces together and make adjustments so you get
a good fit between the elevator and the stabilizer. Check
the hinge gap and the gap at the counter balance. Make
sure there is clearance between the elevator joiner plate
and the fuselage. Hold half of the elevator aligned to the
leading edge of the stabilizer and ensure the opposite
elevator half is also aligned. Sand or shim the elevator
joiner plate until both halves are aligned to at the leading
edge of the stabilizer.
Practice assembling the elevator, hinges and jointer plate
together without glue so things go smoothly when you
glue it all together.
Apply petroleum jelly (Vaseline) to the center hinge pin
portion of each hinge. This will help prevent glue from
getting into the hinge when gluing then into the elevator.
Avoid getting petroleum jelly on the barbed portion of
the pin. If you do clean it off with alcohol.
Use painter masking tape to prevent glue from getting
where you don’t want it.

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We suggest using 30 minute epoxy for the elevator
jointer plate and polyurethane glue for the hinges. (Add
a drop of water to each hinge hole if using polyurethane
glue like Gorilla Glue.This type of glue activates with
moisture.)
Begin the final assembly of the elevator by adding
glue to the horizontal stabilizer hinge holes then
insert hinges. (If using Gorilla Glue it will only take a
few drops per hinge. Use a pin to push the glue into
the hole.)
Add epoxy to the joiner slot and glue to the hinge
holes of one half of the elevator then partially slide it
onto the hinges.
Insert the jointer plate through the fuselage then into
the elevator half.
Add epoxy to the joiner slot and glue to the hinge
holes of the second elevator half then slide it onto
the hinges and jointer plate.
Push both elevator halves into position and wipe
away any epoxy that has squeezed out.
Watch for glue expanding around the hinges and
wipe away with alcohol as needed.
Move the elevator up and down to make sure it has
full travel. It won’t hurt to apply additional
petroleum jelly to the hinges.
Tightly tape the gap between the horizontal stabilizer
and the elevator counter balance while the glue and
epoxy dry.
You may also use boards and clamps to hold the halves
aligned.
Carefully remove “masking”tape before the epoxy fully
sets. But do not remove the tape at the stabilizer and
elevator counter balance until epoxy is fully cured.