Extreme Flight 60 EXTRA 300 EXP User manual

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52" EXTRA 300 EXP
Electric ARF
Copyright 2016 Extreme Flight

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Greetings and congratulations on your purchase of the Extreme Flight RC
52" Extra 300 EXP ARF!
This new Extra is the first in a series of midsized electrics built around the
new Xpwr T3910 brushless outrunner. This size aircraft delivers big plane
performance in a package that is easy to transport and maintain at a very
reasonable price point.
The 52" Extra is loaded with all of the groundbreaking tech first brought to
market in the 48" EXP models including generous use of carbon fiber and
fiberglass material to add strength while keeping overall weight very low. The
result is a very robust airframe capable of handling most aerodynamic loads
while remaining lightweight for best performance. The Extra excels in all
modern aerobatic flight regimes including low and slow 3D, fast and
aggressive XA and ultra precise precision flight.

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Tips for Success:
1. Before starting assembly, take a few minutes to read the entire instruction
manual to familiarize yourself with the assembly process.
2. Please take a few minutes and go over all the seams on the aircraft with a
covering iron on a medium heat setting.
3. Use a fresh bottle of thin CA with a fine glue tip when attaching the CA
hinges. This will ensure that the proper amount of CA wicks into the hinge
and surrounding balsa wood and creates a proper bond between the wood and
hinges.
4. Apply a couple drops of CA to high stress areas such as anti-rotation pins,
landing gear mounts, servo trays and motor box joints .
5. When applying decals, first clean the area where the decal will be applied
with alcohol. Mist the area lightly with Windex before applying the decal
which will allow you to properly position it, then use a rubber squeegee to
push all of the liquid from under the decal. This will result in very few air
pockets trapped under the decal.
6. Take the time to properly balance and trim your aircraft and set up rates
and exponential values. Your flying experience will be greatly enhanced by
doing this.
Please note: The assembly of the 52" Extra is almost
identical to the assembly process of the previously
released EXP models. Some photos will show the
previous model component assembly steps.

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Items needed for completion
-Masking tape
-Hobby knife with #11 blades
-Razor saw
-Fresh bottle of thin and medium CA
-Blue Loctite.
-Silicon based glue (Zap-A-Dap-A-Goo, etc.)
-Electric drill with an assortment of small drill bits.
-Small flat head and Phillips head screw drivers.
-Standard and needle nose pliers.
-Metric balldriver or allen key set.
-4 micro metal geared servos. All flight testing was performed with Hitec HS-5087MH
digital servos.
-Xpwr T3910 Brushless Outrunner motor.
-Airboss Elite 80 Amp ESC (Timing must be set to high with the Xpwr 3910 motor).
-4S 2500-3300 mah LiPo battery.
-XOAR 14x8 or 15x7 PJN propeller.
-57mm Extreme Flight spinner.
-2 Extreme Flight 28awg 18"extensions for the 2 rear servos and 2 6"extensions to go
between the receiver and the aileron servo leads.
-Adhesive backed Velcro and Velcro strap for ESC mounting and battery retention.
-Extreme Flight lightweight aluminum servo arms for ailerons and rudder, a G10 arm is
included for elevator.

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Let's begin!
1. Locate the 2 wing panels with ailerons as well as the 2 G10 aileron control
horns and base plates. Remove the ailerons from the wing and remove the
covering over the slot for the aileron horn on the bottom of the aileron with a
sharp hobby blade. Make sure you are doing this on the bottom of the
aileron!
2. Scuff the portion of the control horn that will be glued into the aileron with
sandpaper.

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3. Use a glue tip on your bottle of medium CA and apply glue to the slot as
well as to both sides of the control horn. Insert the control horn into the
baseplate and then into the slot and make sure it seats properly against the
surface of the aileron. Wipe away any excess glue with a soft cloth soaked in
Acetone.

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4. Remove the covering from the aileron servo location and make sure the
hinges are centered in their slots.
5. Slide the aileron into position on the hinges and secure with several drops
of fresh thin CA. This process is much easier and more effective if a fine glue
tip is used. Make sure to deflect the surface as pictured while applying the
CA.

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6. Use the screws provided by the servo manufacturer to secure the aileron
servo in the designated location. Make sure the output shaft is positioned
toward the leading edge of the wing.
7. Locate the 2 threaded aileron pushrods that are the same size and 4 micro
ball links along with 4 2mm screws, nuts and washers. Thread the ball links
onto each end of the pushrods and secure to the servo arm and control horn
with the 2 mm hardware as shown in the picture. We recommend the use of
the Extreme Flight lightweight electric servo arms as shown. Please note the
orientation of the pushrod in relation to the control horn.
Repeat this process for the other wing half.

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8. Locate the carbon fiber main landing gear, 2 axles, 2 locking nuts, 2
wheels, 2 wheel collars and the 2 wheel pants from the hardware package.
Place the threaded portion of the axle through the hole in the carbon gear and
screw the lock nut onto the axle, but do not tighten completely. Place the
wheel onto the axle and secure with a wheel collar. There is a slot pre-cut in
the wheel pant to allow it to fit over the axle. Before installing the wheel pant
place a drop of silicon based glue onto the wheel pant just above the pre-cut
slot. This will prevent the wheel pant from rotating, but allow it to move in
the case of a mishap which may help to prevent damage. Slide the wheel pant
into position over the axle and tighten the nut on the axle, taking care to make
sure the wheel pant is positioned properly. Repeat this process for the
remaining wheel pant. Again this is probably better explained in the
following series of pictures.

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9. Locate the fuselage, 2-3mm socket head cap bolts and 2 washers. Secure
the landing gear to the fuselage by inserting a 3mm screw into a washer,
through the carbon fiber gear and into the pre-installed blind nut in the
fuselage. Make sure to use a drop of blue Loctite on each screw to prevent
them from backing out.
10. Locate the horizontal stabilizer/elevator assembly and slide the elevator
off of the hinges. Use a razor saw to remove portion of the rudder post
located behind the elevator slot.

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11. Insert the stabilizer into its slot and the carbon fiber wing tube into the
plastic sleeve. Use a ruler to insure that the stabilizer is centered in its slot
and compare the stabilizer to the wing tube to make sure it is properly
aligned. Sand or shim the slot if necessary to ensure proper alignment.
Secure the stabilizer with CA.
12. Remove the covering over the left slot on the bottom of the elevator where
the elevator control horn will be installed. Scuff the portion of the control
horn that will insert into the elevator with sandpaper. Slide the horn into the
baseplate and secure the control horn with medium CA.

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13. Slide the elevator onto the hinges in the stabilizer and secure with thin
CA. Again a fresh bottle of CA and a fine glue tip work best here.
14. Remove the covering over the slot in the lower left side of the rudder
where the rudder control horn will be installed. Scuff the portion of the
control horn that will glue into the surface and slide it through the baseplate.
Secure the rudder control horn with medium CA.

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15. Using the same process as with the ailerons and elevator, slide the rudder
onto the hinges and secure to the vertical stabilizer with thin CA.
16. Locate the carbon fiber tailwheel assembly in the hardware package.
Secure the tailwheel bracket to the bottom rear of the fuselage with the
provided wood screws. Make sure the pivot point of the assembly is over the
hinge line of the rudder for best results.
17. Secure the tiller using the provided screw, but do not over tighten as the
tiller should be able to move on the screw as the rudder is deflected.

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18. Place the tailwheel wire in the proper position, aligned with the rudder
and lock into place with the 2 set screws.
19. Use the hardware provided with the servos to install the rudder and
elevator servos in their respective location in the rear of the aircraft. From
the pilot's perspective the rudder servo mounts on the left side of the fuselage
and the elevator servo mounts on the right side. Both servos should have the
output shaft oriented toward the front of the aircraft.
20. The rudder and elevator servo linkages assemble and are installed just
like the aileron linkage. For maximum elevator and rudder travel we have
included two G10 control horns which are bolted to the stock servo arm
provided with the servo. We have found it easiest to tack glue the G10 arm to
the nylon arm and then using the holes in the nylon arm as a guide, drill
through the composite arm. Secure the arm with a small bolt and nut. The
remaining portion of the linkage installation is the same as the other control
surfaces. Alternately you can use the Extreme Flight lightweight electric servo
arm for the rudder servo, however there is not enough room below the bottom
of the stab to use this arm for the elevator.

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21. Next lets mount the Xpwr T3910 motor to the airframe. First go over all
of the motorbox joints with thin CA! Secure the radial X mount and prop
adapter to the motor with the supplied hardware. Use the supplied 4mm
socket head cap bolts and washers to secure the motor to the front of the
motor box. Be sure to use Loctite on all bolts!
22. Mount the ESC to the bottom of the motor box using Velcro straps or
nylon cable ties.

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23. For quick, easy and accurate mounting of the cowl we recommend the
following method. Tear 4 short pieces of masking tape from a roll. Place each
piece of tape on the side of the fuselage so that each piece corresponds with
one of the 4 cowl mounting tabs. Use a fine tipped marker to mark the
location of the center of each mounting tab. Roll the tape back and slide the
cowl into position. Install an Extreme Flight 57mm spinner onto the motor
shaft for reference and once satisfied with the cowl position roll the tape back
into place and secure the cowl. Use a 1/16" drill bit to drill a hole at the
location of the dot on each piece of tape. Remove the tape and secure the cowl
with 4 of the included small wood screws that have integrated washers. Very
simple!

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24. Place a strip of Velcro onto the battery tray and onto your battery and use
a Velcro strap around the battery and tray to prevent the battery from being
ejected during high G maneuvers. Mount your receiver on the wing retention
cross brace.
25. If using the included Side Force Generators now is the time to mount
them. Each SFG mounts using 2 3mm thumb screws and 2 clear plastic
washers. There is also a clear spacer that fits between the wing tip and SFG
to prevent the SFG from interfering with the aileron movement. There are 2
laser cut holes in each SFG which correspond with 2 laser cut holes in the tip
of each wing. Insert the bolts into the plastic washers and through the laser
cut holes in the SFG and the holes in the clear spacer. Mount the SFG onto
the wing tip by inserting the 2 bolts into the pre-installed blind nuts in the tip
of the wing.

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26. Slide the carbon fiber wing tube into the fuselage and the wings onto the tube. Secure
to the fuselage using the 2 3mm bolts and washers inserted through the tabs and into the
pre-installed blind nuts.
Set-up and flying tips
The CG range for the 52" Extra EXP starts at the front of the wing tube and
extends to the rear of the wing tube. There is plenty of room on the battery
tray to move your battery to achieve this CG location. Depending on your
flying style you can adjust the position of the battery to alter the CG to
accommodate your preferences. For this type of aircraft where I am going to
predominantly fly aggressive 3D I typically set the airplane up with a neutral
CG, meaning that when the aircraft is flown inverted straight and level it
requires no down elevator to maintain altitude. If your flying style leans more
toward precision aerobatics then I recommend setting your CG using the 45
degree line test. Fly the aircraft from left to right or right to left, whichever
direction you are more comfortable with at 3/4 to full throttle. Pull the
aircraft to a 45 degree up line and establish this line and immediately roll the
aircraft inverted. Establish this line and let go of the elevator stick. Ideally
the aircraft will continue to track on that 45 degree line for several hundred
feet before slowly starting to level off. Adjust the position of your battery to
achieve this flight condition. I also highly recommend taking the time to
properly set up your rates and exponential settings. Setting up low rates for
precision maneuvers and high rates for aggressive aerobatics and (continued)