Black Horse Model Extra 300S User manual

SPECIFICATION
MadeinVietnam.
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Wingspan: 1,600 mm 63 in.
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Length : 1,450 mm 55.5 in.
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Weight : 3.2 Kg 7.04 Lbs.
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Engine : 61 cu.in 2 stroke.
91 cu.in 4 stroke.
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Radio : 4 channels.
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Servo : 6 servos.
INSTRUCTIONMANUALBOOK

EXTRA 300S. Instruction Manual
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This instruction manual is designed to help you build a great flying aeroplane. Please read this
manual thoroughly before starting assembly of your EXTRA 300S. Use the parts listing below to
identify all parts.
WARNING.
Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it is
capable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOU
ASSUME ALL RISK & RESPONSIBILITY.
IfyouareinexperiencedwithbasicR/CflightwestronglyrecommendyoucontactyourR/Csupplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
proceduresdesignedtohelpthenew pilotonhiswaytosuccessfulR/C flight.Theywillalso beable
to advise on any insurance and safety regulations that may apply.
TOOLS & SUPPLIES NEEDED.
Thick cyanoacrylate glue.
30 minute epoxy.
5 minute epoxy.
Hand or electric drill.
Assorted drill bits.
Modellingknife.
Straight edge ruler.
2mm ball driver.
Phillips head screwdriver.
220 grit sandpaper.
90° square or builder’s triangle.
Wire cutters.
Masking tape & T-pins.
Thread-lock.
Paper towels.
Some more parts.
HARDWAREPACK
COWLING.
Landinggear.....
Toavoid scratching yournew airplane,do not
unwrap the pieces until they are needed for
assembly. Cover your workbench with an old
towel or brown paper, both to protect the
aircraftand toprotect thetable. Keepa couple
of jars or bowls handy to hold the small parts
after you open the bag.
Pleasetrialfitalltheparts. Makesureyouhave
the correct parts and that they fit and are
alignedproperly beforegluing!Thiswillassure
proper assembly. EXTRA 300SARF is hand
made from natural materials, every plane is
unique and minor adjustments may have to
be made. However, you should find the fit
superior and assembly simple.
The painted and plastic parts used in this kit
are fuel proof. However, they are not tolerant
of many harsh chemicals including the
following: paint thinner, C/A glue accelerator,
C/A glue debonder and acetone. Do not let
these chemicals come in contact with the
colors on the covering and the plastic parts.
PARTS LISTING.
FUSELAGE ASSEMBLY
(1) Fuselage.
WING ASSEMBLY
(1) Right wing half with pre-installed
aileron.
(1) Left wing half with pre-installed
aileron.
Tail section assembly
(1) Vertical stabilizer with pre-
installedrudder.
(1) Horizontal stabilizer with pre-
installedelevator halves.
SUGGESTION.
NOTE.

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+ This is not a toy
+ Be sure that no other flyers are using your
radio frequency.
+ Do not smoke near fuel
+ Store fuel in a cool, dry place, away from
children and pets.
+ Wear safety glasses.
+Theglowplug clipmustbesecurely attached
to the glow plug.
+ Do not flip the propeller with your fingers.
+ Keep loose clothing and wires away from
thepropeller.
+ Do not start the engine if people are near.
Do not stand in line with the side of the
propeller.
+ Make engine adjustments from behind the
propeller only. Do not reach around the
spinningpropeller.
SAFETY PRECAUTION.
 1. Install the rubber grommets and brass
eyelets onto the aileron servo.
4.Drill1,5mm pilotholes through theblock
of wood for each of the four mounting screws
providedwiththeservo.Installservointoaileron
servo tray as same as picture below.
 2. Using a modeling knife, remove the
covering servo tray.
INSTALLING THEAILERON SERVOS.
Bottom side.
3) Using the thread as a guide and using
masking tape, tape the servo lead to the end
of the thread: carefully pull the thread out.
When you have pulled the servo lead out,
remove the masking tape and the servo lead
from the thread.
Electric wire.
Thread.
Remove the
covering.
Bottom of wing.

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Servo
cover.
Repeat the procedure for the other
wing half.
C/Aglue.
Trim andcut.

EXTRA 300S. INSTRUCTION MANUAL
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3x40mm.
Nilon control clasp.
M3locknut.
ControlhornofAileron
AileronControlhorn
C/Aglue
Remove the
covering.
C/Aglue.

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Repeat the procedure for the other wing
half.
INSTALLING THE AILERON
LINKAGES.
1. Working with the aileron linkage for
now, thread one clevis onto one of the
threaded wires.
2. Attach the clevis to the outer hole in the
control horn. Install a silicone tube on the
clevis.
4. Locate one nylon servo arm, and using
wire cutters,remove all but one of the arms.
Using a 2mm drill bit, enlarge the third hole
outfromthecenterofthe armtoaccommodate
the aileron pushrod wire.
3. Plug the aileron servo into the receiver
andcentertheservo.Installthe servoarmonto
the servo. The servo arm should be
perpendicular to the servo and point toward
the middle of the wing.
5.Usingpliers,carefullymake a90 degree
bend down at the mark made. Cut off the
excess wire, leaving about 4mm beyond the
bend.
6.Insertthe 90degree bend down through
the hole in the servo arm. Install one nylon
snap keeper over the wire to secure it to the
arm. Installthe servoarm retainingscrew and
remove the masking tape from the aileron.
M2locknut.
M2clevis. Snapkeeper.
Repeat the procedure for the other
wing half.
Bend and
cut after

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INSTALLING THE ENGINE MOUNT.
See pictures below:
cut.
3.5x25mm.
4x25mm.

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Blow through one of the lines to ensure
the fuel lines have not become kinked inside
the fuel tank compartment. Air should flow
througheasily.
9. To secure the fuel tank in place, apply a
bead of silicon sealer to the forward area of
thetank, whereit exitsthefuselage behindthe
enginemountingbox andtotherearofthetank
at the forward bulkhead.
5. Test fit the stopper assembly into the
tank. It may be necessary to remove some of
the flashing around the tank opening using
amodeling knife. Ifflashing is present, make
sure none of it falls into the tank.
8. Feed three lines through the fuel tank
compartment and through the pre-drilled hole
in the firewall. Pull the lines out from behind
the engine, while guiding the fuel tank into
place. Push the fuel tank as far forward as
possible,the frontofthetankshould justabout
touch the back of the firewall.
6. When satisfied with the alignment of the
stopper assembly tighten the 3mm x 20mm
machine screw until the rubber stopper
expands and seals the tank opening. Do not
over tighten the assembly as this could cause
the tank to split.
7. Using a modeling knife, cut 3 lengths of
fuel line 150mm long. Connect 2 lines to the 2
vent tubes and 1 line to the fuel pickup tube in
the stopper.
Tie wrap.
When the stopper assembly is installed
in the tank, the top of the vent tube should
rest just below the top surface of the tank.
It should not touch the top of the tank.
INSTALLING THE STOPPER ASSEMBLY
1.Thestopper hasbeen pre-assembledat
the factory.
2.Using amodeling knife,cut onelength of
siliconfuelline (thelength ofsilicon fuellineis
calculated by how the weighted clunk should
restabout 8mmaway fromtherearofthetank
andmove freelyinside thetank). Connectone
end of the line to the weighted clunk and the
other end to the nylon pick up tube in the
stopper.
3.Carefully bendthesecondnylontubeup
ata 45degreeangle (usingacigarettelighter).
This tube will be the vent tube to the muffler.
4.Carefully bendthethirdnylontube down
ata 45degreeangle (usingacigarettelighter).
This tubewill bevent tubeto thefuelingvalve.
FUEL TANK.

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Locate the long piece of wire used for the
throttlepushrod. Oneendofthewire hasbeen
pre-bend in to a “Z” bend at the factory. This
“Z” bend should be inserted into the throttle
armofthe enginewhentheengine isfittedonto
theengine mount.Fittheengineto theengine
mount using the screws provided.
INSTALLING THE ENGINE.
Do not secure the tank into place
permanently until after balancing the
airplane. You may need to remove the tank
to mount the battery in the fuel tank
compartment.
Tie wrap.
Fueltank.
128mm.
Secure.

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2. While keeping the back edge of the
cowl flush with the marks, align the front of
thecowlwiththecrankshaftoftheengine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening. Hold the cowl firmly in place using
pieces of masking tape.
4. Installthemufflerandmufflerextension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
andfuel fillervalve.
3. Slide the cowl back over the engine
andsecure itin placeusing fourwood screws.
See picture below.
COWLING.
1. Slide the fiberglass cowl over the en-
gine and line up the back edge of the cowl
with the marks you made on the fuselage.
Trimandcut.
Pushrod wire.

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1. Install the rubber grommets and brass
colletsintothe elevatorservo.Testfittheservo
into the servo tray.
2. Mount the servo to the tray using the
mounting screws provided with your radio
system.
ELEVATOR INSTALLATION.
Installthe spinnerbackplate,propellerand
spinner cone. The spinner cone is held in
place using two 3mm x 15mm wood screws.
Machine screw.
INSTALLING THE SPINNER.
Elevator servo.

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3. Markthe shapeoftheverticalontheleft
and right sides onto the horizontal stabilizer
using a felt-tip pen
4. Remove the stabilizer. Using the lines
youjustdrew asa guide,carefully removethe
coveringfrom betweenthem usingamodeling
knife.
When cutting through the covering to
remove it, cut with only enough pressure
to only cut through the covering it’s self.
Cutting into the balsa structure may
weaken it. This could lead to possible
failure during flight
2. Draw a center line onto the horizontal
stabilizer. Then slide the horizontal into the
fuselage.
Center line.
HORIZONTAL STABILIZER.
See pictures below:
1) Using a modeling knife, cut away the
covering from the fuselage for the stabilizer
and remove it.
Check tomarksure thewing andstabilizer
are paralell. If they are not, lightly sand the
openinginthefuselageforthestabilizeruntil
the stabilizer is paralell to the wing.
Remove covering.
Bottom side.
Remove covering.
Pen.
Bottom side.

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ELEVATOR CONTROL HORN
INSTALLATION.
Elevator control horn install as same as the
wayofaileroncontrolhorn.Pleaseseepictures
below.
5. When you are sure that everything is
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
topand bottomofthestabilizermountingarea
and to the stabilizer mounting platform sides
inthefuselage.Slidethestabilizerinplaceand
re-align. Double check all of your
measurements one more time before the
epoxycures. Removeanyexcess epoxyusing
a paper towel and rubbing alcohol and hold
the stabilizer in place with T-pins or masking
tape.
6. Afterthe epoxy has fully cured, remove
the masking tape or T-pins used to hold the
stabilizer in place and carefully inspect the
glue joints. Use more epoxy to fill in any
gaps that were not filled previously and
clean up the excess using a paper towel and
rubbingalcohol.
C/Aglue.
Epoxyglue.
3x40mm.
Nilon control clasp.
M3locknut.
Controlhornofelevator.
C/Aglue.
Pen.
Drill 1 hole with 6 mm diameter.

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C/Aglue.
ELEVATOR PUSHROD INSTALLATION.
Elevatorpushrodinstallassameastheway
of aileron pushrod.
Bend andcutafter
Bottom side
Elevator
control horn.
Elevator
control horn.
Elevator
pushrod. Elevator
pushrod.
Elevator servo.
Elevator servo.
Snapkeeper.

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VERTICAL INSTALLATION.
2. Slide the rudder into the fuselage as
same as picture below.
Control clasp.
Hinge.
Remove
covering.
Snapkeeper.
Hingeslot.
4. Now, remove the rudder and using a
modeling knife, carefully cut just inside the
markedlinesandremovethefilm oftherudder.
Just as you did with the horizontal stabilizer,
make sure you only press hard enough to cut
the film, not the balsa rudder.
3. Markthe shapeoftheverticalontheleft
and right side on the rudder using a felt-tip
pen.
5. Put the vertical stabilizer back in
place. Using a triangle, check to ensure
that thevertical stabilizeris aligned90 degree
to the horizontal stabilizer.
Pen.
Remove
covering.
Epoxyglue.
Rudderservo
1. Using amodeling knife, cut awaythe
covering from the fuselage for the stabilizer
and remove it.
Also carefully remove the covering from
the horizontal fin as below the lines which
you drew as same picture below.

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6) When you are sure that everything is a
aligned correctly, mix up a generous amount
of 30 minute epoxy. Apply a thin layer to the
slotin themountingplatform andtothevertical
stabilizer mounting area. Apply epoxy to the
lower rudder hinge. Set the stabilizer in place
and re-align. Double check all of your
measurements once more before the epoxy
cures. Remove any excess epoxy using a
paper towel and rubbing alcohol and hold the
stabilizerinplacewithT-pinsor maskingtape.
Allowtheepoxytofullycurebeforeproceeding.
RUDDER CONTROL HORN
INSTALLATION.
Rudder control horn install as same as the
wayofaileroncontrolhorn.Pleaseseepictures
below.
RUDDER PUSHROD INSTALLATION.
Rudder pushrod install as same as the way
of aileron pushrod.
C/Aglue.
C/Aglue.
Markpoint
Drill 6mm a hole of the mounting rudder
control horn on to the rudder with 6mm
diameter.
Rudder
control
Snapkeeper.
ControlhornofRudder.
Nilon control clasp.
M3locknut.
3mm x 40mm.

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INSTALLING THE THROTTLE PUSHROD.
1. Install one adjustable metal connector
through the third hole out from the center of
one servo arm, enlarge the hole in the servo
arm using a 2mm drill bit to accommodate the
servoconnector. Removethe excessmaterial
from the arm.
After installing the adjustable metal
connector apply a small drop of thin C/A
to the bottom nut. This will prevent the
connector from loosening during flight.
Servo arm.
Connector.
Throttle servo.
Throttlepushrod.
Rudderpushrod.
Elevatorpushrod.
INSTALLINGTHERECEIVERANDBATTERY.
 1. Plug the servo leads and the switch
leadinto the receiver. You may want to plug
anaileronextensioninto the receiver to make
plugging in the aileron servo lead easier
when you are installing the wing . Plug the
battery pack lead into the switch.

2. Wrap the receiver and battery pack in
the protective foam to protect them from
vibration. Use a rubber band or masking tape
to hold the foam in place.

1. Cutout theswitch holeusingamodeling
knife. Use a 2mm drill bit and drill out the two
mounting holes through the fuselage side.

2. Secure the switch in place using the
two machine screws provided with the radio
system.
INSTALLING THE SWITCH.
Switch.

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MAIN GEAR INSTALATION.
PARTSREQUIRED
1) The blind nuts are already mounted in-
side the fuselage.
2)Theholes inthe landinggear shouldbe
to accept the mounting bolts.
3) Using the hardware provided, mount
the main landing gear to the fuselage.
 3. Position the battery pack and receiver
behindthe fueltank. Usethetwo lightplywood
pieces, placed over the battery and receiver
and glue to the fuselage sides to hold the
battery and receiver securely in place. Use
15mm triangle pieces glued between the
fuselage sides and the plywood pieces to
reinforce the joints.
Donotpermanentlysecure thereceiverand
battery until after balancing the model.

4. Using a2mm drillbit, drilla holethrough
the side of the fuselage, near the receiver, for
the antenna to exit.
Receiver.
Tie wrap.
Battery.
Tie wrap.
Throttle pushrod.
Rudder pushrod.
Elevator pushrod.
Elevator pushrod.

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C/Aglue.
Cut.
Trim.
1)Assembleand mountingthewheel pants
as shown in the following pictures.
Drill a hole.
Trim.
Bottom side of fuselage

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 2. Using a pen, mark the locations of the
two mounting screws. Remove the tail wheel
bracket and drill 1mm pilot holes at the loca-
tions marked.
 3. Secure the tail wheel bracket in place
using three 3mm x 12mm wood screws. Be
careful not to overtighten the screws.
2) A drop of C/A glue on the wheel collar
screws will help keep them from coming lose
duringoperation.
Repeat the process for the other wheel.
 1. Set the tail wheel assembly in place
on the plywood plate. The pivot point of the
tail wheel wire should be even with the rud-
derhingelineandthetailwheelbracketshould
be centered on the plywood plate.
MOUNTING THE TAIL WHEEL
BRACKET.
Landing gear.
3 X 12mm.