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.)