Extreme Flight 78" EXTRA 300 ARF User manual

125" EXTRA 300
ARF
Assembly Manual

Congratulations on your purc ase of t e new Extreme Flig t RC 125" Extra
300. T is airframe is t e culmination of several years of design, revision and
flig t testing, resulting in a top quality competition grade aircraft. T is
airframe comes ig ly prefabricated allowing one to assemble and fly t e
Extra wit minimal effort.
T e Extra 300 was designed to excel at IMAC and invitational sequence
flying. It is also a very capable 3D aircraft in t e ands of an experienced
pilot. T e Extra's fuselage as been stretc ed to t e maximum allowable limit
providing for an aircraft t at tracks extremely well and will certainly prove
itself a contender in t e upper classes of competition flying.
T is aircraft is intended for experienced pilots wit a t oroug knowledge of
giant scale aircraft power systems and radio/servo/linkage set-ups. As suc
t e assembly manual is brief and outlines t e important points t at must be
addressed t at are unique to t is airframe. Personal preference based on
previous experience will dictate finis ing details suc as radio/battery
installation, fuel tank c oice, installation and plumbing, grap ics c oices and
installation. If you are not experienced enoug to make t ese decisions I
ig ly recommend t at you start wit a smaller, less expensive aircraft in t e
30cc-50cc range to learn t e important basics of flying and maintaining
gasoline powered aircraft before stepping up to suc an expensive and
potentially dangerous aircraft.
Extreme Flig t RC, LTD. in no way accepts or assumes responsibility or
liability for any damage, destruction of property, injury or deat associated
wit t e use of t e final user assembled product. If you are not willing to
accept any and all responsibility for t e use of t is aircraft please return it to
t e place of purc ase immediately.

Wing assembly
(Please note t at we ig ly recommend t e use of 3 ultra torque servos for aileron
actuation. We did extensive testing using bot 2 and 3 servos and t e gain in roll and snap
performance using 3 servos is by far wort t e investment in additional servos and t e time
required to properly set t em up).
1. First I ig ly recommend t at you take a few minutes and go over all seams wit a
covering iron on a medium setting, paying special attention to stripes and areas w ere
covering overlaps.
2. T e ailerons use a unique pocket inge system. T ere are two rods t at act as t e inge
pins for t is system, one inserted at t e tip of t e wing, t e ot er t roug t e root. Use a
flat ead screw driver to back out t e t readed portion of t e rods and put a few drops of
blue Loctite on eac . Re-tig ten t e t readed portion into t e t readed insert. Make sure
to do t is for bot wings.
3. Next we'll install t e aileron control orns. It is imperative t at you pay close attention
during t is step. In order to provide t e proper linkage geometry eac set of aileron
control orns as a ole drilled in a different location to compensate for t e varying
t ickness of t e wing and aileron. T e picture below illustrates t e proper location of eac
set of orns.

4. Use a s arp obby blade to remove t e covering over t e slots at eac of t e 3 locations
w ere t e dual truss control orns will be installed. Place t e orns into t e base and
insert into t e slots in t e aileron. Trace around t e base wit a fine tipped felt marker.
5. Use a s arp obby blade to remove t e covering 1/16" inside t e line you ave traced so
t at t e fiberglass base plate will cover t e exposed edges and prevent t em from lifting.

6. Scuff t e portion of t e control orns t at will be glued into t e aileron wit sandpaper
to remove t e glossy s een and clean wit denatured alco ol. Mix up some 30 minute
epoxy (I prefer Mercury Ad esives 30 minute formula). Use a piece of pus rod or old
obby blade to fill t e slots in t e aileron wit epoxy. Coat t e entire area of t e orns t at
will insert into t e aileron and t e bottom of t e base plate wit epoxy. Insert t e orns
into t e slot and pus down until t ey are flus wit t e base plate. Use a paper towel
soaked wit denatured alco ol to remove t e excess epoxy. Insert a 3mm bolt t roug t e
oles in t e orn to insure proper alignment. Repeat t is process for t e remaining control
orns.

7. Use a s arp obby blade to remove t e covering at t e location of eac servo and seal
t e edges wit a ot trim iron. Take a few minutes and saturate all joints of t e servo
mounting trays wit CA.
8. Use t e manufacturer supplied ardware to mount t e servos in t eir proper location
wit t e servo s aft toward t e trailing edge of t e wing. You will need to use 1- 36", 1-
24", and 1-12" extension to get t e servo leads out of t e wing. We recommend t e use of a
1.5 inc aluminum servo arm. T read 2 ball links onto t e titanium pus rod and install
t e pus rod as s own in t e picture using t e supplied ardware. It will be necessary to
place a was er on eac side of t e ball link between t e brass ball and t e fiberglass control
orn to prevent binding.

9. It is ig ly recommended t at you use a servo programmer, Matc box or power
distribution unit to make sure all 3 servos work in unison. We use t e Hitec 7955s and
7950s in our aircraft in conjunction wit t e Hitec programmer and ave been able to get
t e servos matc ed perfectly wit very little current draw.
Elevator/stab assembly
10. Just as you did wit t e wings, take a few moments to go over all t e seams and stripes
wit a ot iron to ensure all edges are sealed.
11. Use a flat ead screw driver to back out t e t readed portion of t e inge pin rod at
t e root of t e elevator. Place a couple drops of blue Loctite on t e t reads and re-tig ten
t e inge pin rod. Repeat for t e ot er stab/elevator alf.
12. T ere are provisions to use 2 elevator servos per alf included wit t e Extra. We
ave found one ultra torque servo to be sufficient (Hitec 7955 or 7950, JR 8711 HV, Futaba
9156 or 9157). If using a single servo use t e servo mount furt est outboard on t e stab
and t e corresponding elevator orn slot.
13. Using t e same tec nique as wit t e aileron mount t e elevator control orn as
s own. All of t e elevator orns are identical.
14. Install your servo using t e manufacturer supplied mounting ardware wit t e
output s aft oriented toward t e trailing edge of t e stab. T read a ball link onto eac end
of t e t readed titanium pus rod and install using t e supplied ardware as s own in t e
picture. We use a 1.5 inc aluminum servo arm for elevator actuation. If setting up t e
Extra for precision aerobatics only we suggest using a 1 inc arm for better resolution.

Rudder preparation and installation
15. T is step is also very important-please pay close attention. T ere are 2 sets of control
orns provided for t e rudder. T e larger orn set is to be used if you intend to use a pull-
pull set-up wit t e rudder servos mounted inside t e fuselage under t e canopy. If using 4
elevator servos it is recommended t at you use t e pull-pull option to elp ac ieve proper
CG. A 5 inc servo arm is recommended for proper geometry.
T e smaller orns are to be used if you use a direct drive pus -pull linkage wit 2 servos
mounted in t e rear of t e fuselage. T is is t e preferred met od as it is muc easier to set
up and provides a more direct and powerful means of rudder actuation. T ese orns are
t e same as used for t e elevators.

16. Using t e same met ods as used previously wit t e ailerons and elevator, install t e
fiberglass rudder orns on eac side of t e rudder. T e rudder is inged using t e same
met od as wit t e ailerons and elevators. Place a few drops of blue Loctite on t e
t readed portion of t e rudder inge pin and insert into rudder. Tig ten using a flat ead
screwdriver. T e picture below s ows t e completed assembly using t e direct drive pus -
pull met od. We are using 2 inc servo arms. Please note t at t e output s aft is oriented
toward t e rear of t e aircraft. T is same set-up is to be repeated on t e ot er side of t e
fuselage. T e use of 2 ultra torque servos suc as t e Hitec 7950, JR 8711HV or Futaba
9157 is mandatory.

17. T ere are 2 additional plywood trays included to accommodate various pull-pull set-
ups. One tray allows t e use of up to 3 standard size ig torque servos ganged toget er.
T e additional ardware required for t is set-up is not included in t is kit. Also included
is a tray to allow t e use of a single Seiko industrial grade servo. T ese trays are tabbed to
glue into fuselage under t e canopy.

Fuselage assembly
18. Let's start by getting t e landing gear mounted. Use t e supplied 8mm bolts, nylon
insert lock nuts and was ers to mount t e carbon fiber landing gear to t e bottom of t e
fuselage. T e straig t portion of t e gear leg s ould be oriented toward t e front of t e
aircraft.

19. T e landing gear fairings add a nice scale touc to t e aircraft but are not necessary.
If you wis to use t em, slit t e supplied black neoprene tubing lengt wise wit a s arp
obby knife. Pus t e tubing onto t e rim of t e fairing and secure wit CA. Attac t e
fairing to t e gear wit "Goop" silicon glue. Alternately you can secure t em wit a small
screw as s own in t e p oto above.
20. Install t e supplied axles, w eels and pants onto t e carbon fiber landing gear.

21. Mounting t e engine is quite easy. T ere are laser inscribed reference marks on t e
front of t e engine mounting plate. W en looking at t e front of t e mounting plate t e
vertical line to t e rig t of t e center line s ould be used to allow for rig t t rust offset to
counter spiral slipstream effect. T e distance from t e face of t e engine mounting plate to
t e engine drive was er s ould be 8 1/8 inc es. Use standoffs to ac ieve t is lengt .
Here are a couple of p otos s owing t e installation of t e DA-170 in our Extra.

22. T ere are plywood tabs supplied for mounting your fuel tank. T ese are pus ed up
from inside t e pipe tunnel and s ould be secured wit epoxy. Due to t e wide range of
engines t at will be used a gas tank is not provided. We ave started making our own
tanks from 64 ounce juice bottles using brass fittings available from B&B Specialties.
Please see t e following picture s owing our ome made tank and installation.
23. T rottle servo installation and linkage set-up will depend on t e requirements of t e
engine you are using. As suc t ere are no provisions supplied for t e mounting of t e
t rottle servo.

24. Cowl mounting is very easy! T e cowl is secured wit 3 4mm screws. It is best to
insert t e longest of t e 3 screws into t e bottom of t e cowl and secure first, t en t e top 2
screws as s own. Be sure to use a was er and a generous amount of blue Loctite to prevent
t e screws from backing out.

25. T ere are 2 blind nuts pre-installed in t e rear bottom of t e fuselage for mounting t e
carbon fiber tail w eel assembly. Before installing t is assembly, file flat spots on t e tail
w eel wire so t at all set screws from t e various collars seat properly. Use a drop of blue
Loctite on eac setscrew.
26. Install t e tiller arm on t e bottom of t e rudder along wit t e supplied springs w ic
will steer t e tail w eel.
27. Secure t e stabs to t e fuselage wit t e supplied 3mm bolts and was ers, making sure
to use a generous amount of blue Loctite to prevent t e bolts from backing out.

28. Installation of batteries and radio equipment is up to t e end user and will depend on
t e equipment you c oose to use. T ere are four laser cut oles in t e fuselage t at will
accept t e JR PA004 Super Switc and various ot er units from ot er manufacturers.
29. T e wing is secured to t e fuselage using a combination of a 1/4-20 nylon bolt inserted
into t e wing from inside t e fuselage at t e rear of t e c ord and into t e pre-installed
blind nut in t e wing root and a 4mm bolt t at inserts into t e tongue t at protrudes from
t e wing. T is bolt is secured in t e fuselage using t e pre-installed blind nut.
T is completes t e assembly process for t e Extra. T e Center of gravity for t e Extra is
on t e center of t e wing tube. You may prefer it slig tly in front of or be ind t is position
depending on your flying style. One of t e easiest met ods to c eck CG on an aircraft of
t is size is to tie a t in rope around t e wing tube on eac side of t e fuselage. Slide t e
wings into position and install t e canopy. Lift t e aircraft using t e rope and adjust t e
position of your batteries and radio gear to ac ieve proper balance.
Please note: T e ig quality airfoiled carbon fiber landing gear is very lig tweig t and
plenty strong to andle normal landings. It will not andle side loads well. Be sure to
bleed off speed w en landing before making a turn to prevent from collapsing t e gear.
Periodically inspect t e carbon fiber landing gear and carbon wing and stab tubes for signs
of distress and replace if necessary.
T anks again for your purc ase of t e Extreme Flig t RC 40% Extra 300 ARF. We ope
it brings you as muc excitement and joy as we ave experienced flying ours.
See ya at t e flying field!
C ris Hinson
Extreme Flig t RC