Extreme Flight LEGACY AVIATION 100" Turbo Bushmaster... User manual

100” BUSHMASTER
T URBO
DESIGNED BY
CODY WOJCICK
A V I A T I O NA V I A T I O N
BY
Copyright 2023 Extreme Flight RC

Please take a few moments to read this instruction manual before beginning assembly. We have outlined a
fast, clear and easy method to assemble this aircraft and familiarizing yourself with this process will aid in a
quick, easy build.
Please read the following paragraph before beginning assembly of your aircraft!
THIS IS NOT A TOY! Serious injury, destruction of property, or even death may result from the misuse of this product. Extreme
Flight RC is providing you, the consumer with a very high quality model aircraft component kit, from which you, the consumer,
will assemble a flying model. It is beyond our control to monitor the finished aircraft you produce. Extreme Flight RC will in no
way accept or assume responsibility or liability for damages resulting from the use of this user assembled product. This aircraft
should be flown in accordance to the AMA safety code. It is highly recommended that you join the Academy of Model Aero-
nautics in order to be properly insured, and to operate your model at AMA sanctioned flying fields only. If you are not willing to
accept ALL liability for the use of this product, please return it to the place of purchase immediately.
Extreme Flight RC, Ltd. guarantees this kit to be free of defects in materials and workmanship for a period of 30 DAYS from the
date of purchase. All warranty claims must be accompanied by the original dated receipt. This warranty is extended to the origi-
nal purchaser of the aircraft kit only.
Extreme Flight RC in no way warranties its aircraft against flutter. We have put these aircraft through the most grueling flight
tests imaginable and have not experienced any control surface flutter. Proper servo selection and linkage set-up is absolutely es-
sential. Inadequate servos or improper linkage set up may result in flutter and possibly the complete destruction of your aircraft.
If you are not experienced in this type of linkage set-up or have questions regarding servo choices, please contact us at info@
extremeflightrc.com or 770-887-1794. It is your responsibility to ensure the airworthiness of your model.
BBUUSHSHMMAASSTTERER
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Two points to start: In this build, we will use epoxy glue in several steps. Prompt cleanup of any excess
epoxy is important. We recommend you use denatured alcohol, available at most hardware and home-im-
provement stores.
When you unpack your airplane, note that in order to remove the main hatch, you must release the latch
and then *pull forward* to release the hatch.

Control settings:
Elevator: Low Rate 8-10 deg. 15-20% expo
3D Rate 45 deg. 60-70% expo
Aileron: Low Rate 15-20 deg. 20-30% expo
High Rate 38-40 deg. 60-70% expo (For best roll rate, mix aps to ailerons)
Rudder: Low Rate 20 deg 40-45% expo
High Rate 45 deg. 70-80% expo
Flaps: 40 degrees full deection with 5% down elevator mix at full deection
Power system:
GAS
Desert Aircraft DA 35 Prop: Carbon gas 20 x 8
Great Power GP-38 Prop: Carbon gas 20 x 8, 20 x 9
FlowMaster 14 oz. fuel tank
ELECTRIC
Motor: Xpwr 35cc or 40cc
Standos: Blazing Star Standard Extra Long Stando Set
ESC: Castle Creations HV-120 Edge ESC (Must Use Firmware v 4.22) or Scorpion Tribunus II 130A
Battery: Two 6S 3300-4000 mAh batteries in series (12S) for XPWR 35, or 4000-5000mah for 40cc
Prop: 21x10 electric for 35cc or 22x10 for 40cc
Servos:
Qty. 7 full size, metal gear hi-torque servos (300 oz/in minimum). MKS HV-1220 or better
Qty. 1 throttle servo, MKS HV-1250 recommended.
Qty. 4 Extreme Flight 1.5 inch single servo arms (tapped 3mm) for ailerons
Qty. 3 Extreme Flight 1.5 inch single servo arms (tapped for 3mm) for elevators and rudder
QTY 1 Metal gear mini servo for tailwheel w/ Extreme Flight mini servo arm 1.25”
Servo Extensions:
Qty. 4 Extreme Flight 20 AWG 6 inch for Rx to Ailerons
Qty. 2 Extreme Flight 20 AWG 12 inch for Ailerons
Qty. 1 Extreme Flight 20 AWG 18 inch for Throttle servo
Qty. 4 Extreme Flight 20 AWG 36 inch for Elevators, rudder, and tail wheel
Covering:
Oracover colors Ultracote colors
White/Red/Black/Charcoal/Silver color scheme:
Ferrari Red #23 True Red-#HANU866
White #10 White-# HANU870
Silver #91 Silver-#HANU881
Black #71 Black-#HANU874
Pearl Charcoal #77 Pearl Charcoal-#HANU846
White/Midnight Blue/Cub Yellow color scheme:
Cub Yellow #30 Cub Yellow-#HANU884
Dark Blue #52 Midnight Blue- # HANU885
White #10 White-# HANU870
Wing tube:22x965mm/6x320mm
Stab tube:13x360mm/6x160mm
Main wing incidence:0.5 deg
Stab incidence:0 deg
Right thrust:2 deg
Up/Down thrust:0 deg
Bushmaster 100in.
Fuselage Length: 1978mm/77.9 in.
Wing Span: 2540mm/100 in.
WING AREA: 79dm²/1224.5 sq.in.
2540
935
1978
594
550
SPECS
WingSpan: 100” Spinner: 3.5”
Length: 78” Weight: 16 lbs (elec, no lipo)
Wing area: 1224 sq. in.
Center of Gravity Range (Measured from wing leading edge at root): 3.3-4.25“ (89-108mm)
Our preferred CG is center of the wing tube.
35-38CC / 12S
100” TURBO BUSHMASTER

Control settings:
Elevator: Low Rate 8-10 deg. 15-20% expo
3D Rate 45 deg. 60-70% expo
Aileron: Low Rate 15-20 deg. 20-30% expo
High Rate 38-40 deg. 60-70% expo (For best roll rate, mix aps to ailerons)
Rudder: Low Rate 20 deg 40-45% expo
High Rate 45 deg. 70-80% expo
Flaps: 40 degrees full deection with 5% down elevator mix at full deection
Power system:
GAS
Desert Aircraft DA 35 Prop: Carbon gas 20 x 8
Great Power GP-38 Prop: Carbon gas 20 x 8, 20 x 9
FlowMaster 14 oz. fuel tank
ELECTRIC
Motor: Xpwr 35cc or 40cc
Standos: Blazing Star Standard Extra Long Stando Set
ESC: Castle Creations HV-120 Edge ESC (Must Use Firmware v 4.22) or Scorpion Tribunus II 130A
Battery: Two 6S 3300-4000 mAh batteries in series (12S) for XPWR 35, or 4000-5000mah for 40cc
Prop: 21x10 electric for 35cc or 22x10 for 40cc
Servos:
Qty. 7 full size, metal gear hi-torque servos (300 oz/in minimum). MKS HV-1220 or better
Qty. 1 throttle servo, MKS HV-1250 recommended.
Qty. 4 Extreme Flight 1.5 inch single servo arms (tapped 3mm) for ailerons
Qty. 3 Extreme Flight 1.5 inch single servo arms (tapped for 3mm) for elevators and rudder
QTY 1 Metal gear mini servo for tailwheel w/ Extreme Flight mini servo arm 1.25”
Servo Extensions:
Qty. 4 Extreme Flight 20 AWG 6 inch for Rx to Ailerons
Qty. 2 Extreme Flight 20 AWG 12 inch for Ailerons
Qty. 1 Extreme Flight 20 AWG 18 inch for Throttle servo
Qty. 4 Extreme Flight 20 AWG 36 inch for Elevators, rudder, and tail wheel
Covering:
Oracover colors Ultracote colors
White/Red/Black/Charcoal/Silver color scheme:
Ferrari Red #23 True Red-#HANU866
White #10 White-# HANU870
Silver #91 Silver-#HANU881
Black #71 Black-#HANU874
Pearl Charcoal #77 Pearl Charcoal-#HANU846
White/Midnight Blue/Cub Yellow color scheme:
Cub Yellow #30 Cub Yellow-#HANU884
Dark Blue #52 Midnight Blue- # HANU885
White #10 White-# HANU870
Wing tube:22x965mm/6x320mm
Stab tube:13x360mm/6x160mm
Main wing incidence:0.5 deg
Stab incidence:0 deg
Right thrust:2 deg
Up/Down thrust:0 deg
Bushmaster 100in.
Fuselage Length: 1978mm/77.9 in.
Wing Span: 2540mm/100 in.
WING AREA: 79dm²/1224.5 sq.in.
2540
935
1978
594
550
SPECS
WingSpan: 100” Spinner: 3.5”
Length: 78” Weight: 16 lbs (elec, no lipo)
Wing area: 1224 sq. in.
Center of Gravity Range (Measured from wing leading edge at root): 3.3-4.25“ (89-108mm)
Our preferred CG is center of the wing tube.
35-38CC / 12S
100” TURBO BUSHMASTER
BBUUSHSHMMAASSTTERER
TURBO

A few tips to ensure success:
1. We are very pleased with the level of craftsmanship displayed by the builders in our factory. Through hundreds of grueling
test flights containing maneuvers that no aircraft should be subjected to, our prototypes have remained rigid and completely
airworthy. Having said that, it is impossible for us to inspect every glue joint in the aircraft. Take a few minutes and apply some
medium CA to high stress areas such as the aileron servo mounting trays , landing gear mount, anti rotation pins, wing and stab
root ribs, etc.
2. Having survived the journey half way around the world while experiencing several climate changes, it is not uncommon for a
few wrinkles to develop in the covering. Fear not! These are not manufacturing defects, and are easily removed with a little bit of
heat. Use a sealing iron to go over all seams, stripes and sharp points in the covering scheme. You may want to apply a drop of
clear fingernail polish at the tip of all sharp points to prevent them from lifting. To remove wrinkles use a 100% cotton tee-shirt
or microfiber cloth and your heat gun and heat the covering while gently rubbing the covering onto the wood with the t-shirt or
cloth. Be careful not to use too much heat as the covering may shrink too much and begin to lift at the edges. Take your time,
and a beautiful, paint like finish is attainable. If you need to repair any covering during the life of your aircraft, the colors are:
Oracover colors Ultracote colors
White/Red/Black/Charcoal/Silver color scheme:
Ferrari Red #23 True Red-#HANU866
White #10 White-# HANU870
Silver #91 Silver-#HANU881
Black #71 Black-#HANU874
Pearl Charcoal #77 Pearl Charcoal-#HANU846
White/Midnight Blue/Cub Yellow color scheme:
Cub Yellow #30 Cub Yellow-#HANU884
Dark Blue #52 Midnight Blue- # HANU885
White #10 White-# HANU870
3. DO NOT SKIMP ON SERVOS! Your aircraft is equipped with very large control surfaces that deflect up to 45 degrees. A lot of
servo power is required to prevent flutter and to maintain the required deflection for maneuvers. We absolutely recommend the
use of METAL GEARED servos with a minimum of 300 oz. inches of torque.
4. Use a high quality epoxy for installing the composite control horns and hinges. We highly recommend the use of Pacer
Z-Poxy 30 minute formula. We have used this glue for many years with zero failures. We also use the Loctite HYSOL brand epox-
ies with their very convenient application gun. If you need to clean any excess epoxy, we recommend a paper towel and dena-
tured alcohol.
5. Your aircraft is built using very modern construction techniques and is very light weight for its size. As with any high per-
formance machine, regular inspection and maintenance is a must. While disassembling your aircraft after a flying session, pay
close attention and inspect glue joints, linkages and loose covering to be sure the airframe is sound. A few minutes spent doing
this will help maintain airframe longevity.
6. We recommend the use of blue Loctite threadlocker when installing fasteners into your aircraft.
BBUUSHSHMMAASSTTERER
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11
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Locate the carbon ber landing gear and the Main Wheel hardware pack. e gear has a front,
and a back. To identify the front, note that the gear sweeps slight forward when installed. Use
4 screws and washers with loctite to install the landing gear as shown. Locate the gear “cu ”
fairings. Test t them to the landing gear. We recommend “Goop” adhesive to attach the cus.
Place masking tape to protect the gear surfeace as shown, apply a large dollop of Goop, slide on
the cu, and ax with masking tape until cured.

BBUUSHSHMMAASSTTERER
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Attach the wheel axles to the landing gear by tightening the locking nuts. Slide on the wheels, and the
wheel spacers. Note the axles have at areas to accept the wheel collar set screws. Put loctite on the set
screw, then install and tighten the wheel collars. Locate the tailwheel and hardware bag. Using loctite,
mount the tailwheel to the fuselage using three screws as shown. Using a small amount of epoxy glue on
the wooden tabs, install the n on the bottom of the fusleage.

BBUUSHSHMMAASSTTERER
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Assemble the tailwheel pushrod with the nylon ball link ends as shown. Remove the covering over the tail-
wheel steering servo mount location as shown. Install the servo wire extension onto the servo and mount
the servo. Install the pushrod between the servo arm and the tailwheel arm with 2mm screws, washers, and
locking nuts. Now is a good time to install the MPX wiring plugs into the pre-t locations in the fuselage,
using wood screws, as shown.

BBUUSHSHMMAASSTTERER
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Locate the stab/rudder (it is pre-hinged for you), its hardware pack, and your servo, wire extesion, and
servo arm. Remove the wood tab on the bottom of the stab as shown. Locate the control horns. Sand
them lightly as shown in the area which will be glued. Assemble the plastic ball links onto the pushrods,
we use a cordless drill to assist. Note that the pushrods has one le hand, and one right hand thread.
Assemble the horns with the sqaure base plate, and the pushrod, with a screw, washers, and locking nuts
as shown.

55
BBUUSHSHMMAASSTTERER
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Remove the covering in the area between the slots on the rudder as shown. Test-t the horn assembly
into the slots. It should be tight, but should go in with moderate force. You may need to clean out the
slots with the hobby knife. Place epoxy glue into the slots and onto the horns. Push the horns into the
slot, seat it rmly. If any epoxy glue squeezes out, clean up with a paper towel soaked with denatured
alcohol.

BBUUSHSHMMAASSTTERER
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66Locate the rudder extension piece which mounts to the fuselage. Check its t as shown. Glue to the fu-
selage with epoxy and use masking tape to hold the position while it cures. Now is a good time to cen-
ter your servos using your radio system or a servo tester. Mount your rudder servo. e servo mounts
inside the vertical stab, go slowly and patiently as you place the servo into its mount. Note that the slot
in the stab is placed to t most common servos and arms, if your servo and arm combo happens to rub
the wood, you can trim the slot using a hobby knife and straight edge.

BBUUSHSHMMAASSTTERER
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77Install your servo arms, use loctite on the arm screws. Attach the pushrod to the arm with screw and
washers, use loctite or a locking nut for safety. Because the pushrod has one le, and one right hand
threads, you can adjust the length of the pushrod by rotating it. Adjust the length of the pushrod so that
the servo arm is 90 degrees as shown when the rudder is centered.
Run your servo wire extension through the plastic tube in the fuselage (now is a good time to also run
your elevator servo extensions). Because we do not expect to remove the vertical stab, we used heat shrink
tubing on the wire connection. Using the carbon mounting tube, install the stab onto the fuselage and
attach with screws and large washers with loctite.

BBUUSHSHMMAASSTTERER
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88Locate the horizontal stabs/elevators. ese are pre-hinged for you. Install the control horns exactly
as you did on the rudder, and assemble the pushrods in the same way. Locate the ns for the stabs and
install with screws and loctite as shown.

BBUUSHSHMMAASSTTERER
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99Locate the elevator servos, make sure they are centered. Plug them into the elevator wire extensions, be-
cause we expect to remove the stabs for transport, we use a servo plug lock on the connection. Using the
front and rear carbon stab tubes, install the stabs and engage the stab locks as shown. Install the servo arm
with loctite and attach the pushrod using loctite or locking nuts.

1010
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Locate the wings and Main Wing hardware pack. e wings are pre-hinged for you. Asemble the ai-
leron and ap pushrods. All 8 control horns are identical. Sand and install them just as you did the
rudder and elevator horns. Attach your servo wire extension to the aileron aervo and feed through
the wing. Some servos will not need an extension in the ap location. Install your servos, and install
servo arms with loctite. Attach the pushrods and adjust to length as shown. We attached the MPX
servo plug and used heat shrink tubing on the connections.

BBUUSHSHMMAASSTTERER
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1111Locate the two carbon wing tubes and slide into the fuselage as shown. Locate the wing strut brackets.Cut
a slit in the covering to allow the fuselage-side bracket to protrude. Loosely install the wing side and fuse-
lage side brackets for the wing struts with loctite, but do not fully tighten. Slide the wings on the tubes all
the way and close the wing latches inside the fuselage. Install the struts with long screws as shown. Once
the struts are installed, then we know the strut brackets are in the correct locations. Tighten the strut
bracket screws fully.

BBUUSHSHMMAASSTTERER
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1212 When the wings are removed from the airplane, the struts lay at against the wing and will t into the
wing bags for transport. e long axle screw on the wing-side strut mount should be locked in place
with a small drop of CA under the screw head.
e rewall of your aircra is marked with two common bolt pattern for engine/motor mounting.
One ts the GP-38/DA-35 gas engines, the other ts the XPWR 35cc and 40cc brushless motors.
Drill the appropriate holes, rst with a small bit diameter bit, then the correct nal size.

BBUUSHSHMMAASSTTERER
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1313 e distance between the rewall surface and the front of the cowl on your bushmaster is
approximately 163mm. is matches the length of common gas engines with their includ-
ed standos/spacers. We do not want a tight spinner-to-cowl t on the Bushmaster, leave
3-4mm for cooling air to enter the cowling.
163mm/ 6.4 in

BBUUSHSHMMAASSTTERER
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1414 If using a gas engine, install onto the rewall, trimming the rewall as necessary to t the carburetor. Use
large diameter washers on the rewall to spread the load of the engine mounting screws, on front and
back if possible. Use loctite to install the screws. Locate the “ottle” hardware pack. Inside is a pushrod
with one threaded end. e threaded end accepts the nylon ball link. is attaches to the carburetor throt-
tle arm. e other end of the pushrod is smooth. e servo arm connector, when mounted on the servo
arm, must spin freely. Tighten the servo connector nut as shown until the connector is snug and doesnt
wobble, but can still rotate freely. Place a drop of medium CA as shown on the nut and apply CA accelera-
tor. Install the throttle servo as shown, install and adjust the linkage, using loctite on the set screw.
MED CA Glue

BBUUSHSHMMAASSTTERER
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1515 Mount the ignition unit to the side of the motor box using adhesive velcro, velcro straps, and cushioning
foam if desired. To cut the bottom of the cowl for clearance and cooling, it is helpful to make a template
from heavy paper or card stock or thin plywood. Use this template to mark the cowl before cutting.
Wear eye and lung protection when cutting the berglass cowl. Go slowly, and test-t frequently while
working. For this installation we trimmed the muer exit tube approximately 20mm (3/4 in). Mount
your fuel tank directly under the wing spar on the tray. Use strong velcro straps. Hook up your fuel lines
for carb, vent, and ll. Remember to place a loop in the vent line as shown so that fuel does not siphon
out of the tank during maneuvers. Install your fuel dot.