Hangar 9 Extra 260 User manual

ASSEMBLY MANUAL
Specifications
Wingspan: ............. 78.25 in (198.8 cm)
Length: ................... 71.25 in (181 cm)
Wing Area: ............ 1134 sq in (73.1 sq dm)
Weight: .................. 12–15.5 lb (5.44–7.0 kg)
Radio: ..................... 4-channel w/6 servos
Recommended Engines:
2-Stroke ............1.20–2.10
4-Stroke ............1.50–2.20
Gas .....................35–50cc
Extra 260


• Awsome IMAC and 3D performer
• Lightweight construction
• Designed by aerobatic veteran Mike McConville
• 90% factory built ARF
• Plug-in wings and stabilizers for easy transport and field assembly

2
Covering Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Other Items Needed (not included in the kit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Additional Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Additional Required Tools and Adhesives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Servo Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Before Starting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Section 1 – Hinging the Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 2 – Sealing the Hinge Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Section 3 – Aileron Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Section 4 – Wing and Stabilizer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Section 5 – Elevator Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Section 6 – Landing Gear Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Section 7A – Engine Installation: Saito. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Section 7B – Engine Installation: DA-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Section 8A – Rudder Servo Installation: Saito . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Section 8B – Rudder Servo Installation: DA-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Section 9 – Tail Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Section 10 – Fuel Tank Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Section 11 – Radio Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Section 12 – Cowling Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Section 13 – Hatch Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Balancing the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Radio Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Control Throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Preflight at the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
2004 Official AMA
National Model Aircraft Safety Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
• White HANU870
• True Red HANU866
• Pearl Blue HANU845
Table of Contents
Covering Colors

3
Large Parts
Fuselage w/Hatch HAN2751
Right Wing Panel w/Aileron HAN2752
Left Wing Panel w/Aileron HAN2753
Stabilizer w/Elevators HAN2754
Rudder HAN2755
Canopy HAN2756
Canopy Hatch HAN2757
Cowl HAN2758
Carbon Fiber Landing Gear HAN2759
Wheel Pant Set HAN2760
Decal Set HAN2761
Carbon Fiber Tail Wheel Bracket HAN2762
Anodized Aluminum Wing Tube HAN2763
Anodized Stab Tubes HAN2764
Radio Equipment
• 6-channel radio system (minimum)
• 1 standard servo for throttle (JRPS537
recommended or equivalent)
• 4 hi-torque servos (JRPS8231
recommended or equivalent)
• 1 hi-torque servo (JRPS8411
recommended or equivalent)
Recommended
JR® Systems
• PCM10X
• XP9303
• XP6102
Recommended Engines
• Saito™ 1.50, 2.20
• Desert Aircraft DA-50
JR XP9303
JR PCM 10X
• Propeller
Saito 1.80: APC 17x6
Saito 2.20: APC 18x8
DA-50: Mejelik 23x8
• Spinner (3 1/4")
• 12" Servo Extension (JRPA098) (2)
• 18" Servo Extension (JRPA099) (2)
• 3D XL 1/2 Servo Arm 4-40: JR (HAN3578) (4)
(5 if using DA-50)
• 3D XL Full Servo Arm 4-40: JR (HAN3576)
(If using Saito 1.80–2.20)
Contents of Kit
Additional Required Equipment
Other Items Needed (not included in the kit)

4
An RC aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open
areas, preferably at AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included
with your radio and engine.
Tools
• 4-40 tap
• Adjustable wrench (small)
• Canopy scissors
• Drill (drill press preferred)
• Drill bit: 1/16", 3/16", 5/64", 7/32", #43, 5/32"
• Drum sander
• Cut-off wheel
• Flat blade screwdriver w/short handle
• Foam: 1/4"
• Hex wrench: 3/32"
• Hobby knife
• Masking tape
• Phillips screwdriver (small)
• Razor saw
• Scissors
• Square
• Syringe
• Tap handle
• Toothpicks
• Velcro straps
Adhesives
• 30-minute epoxy
• Medium CA (cyanoacrylate) glue
• CA remover/debonder
• Pacer Z-42 Threadlock
• Pacer hinge glue (PT-55)
• Formula 560-canopy glue
• Shoo Goo
Other Required Items
• Epoxy brushes
• Felt-tipped pen or pencil
• Measuring device (e.g. ruler, tape measure)
• Mixing sticks for epoxy
• Paper towels
• Petroleum jelly
• Rubbing alcohol
• Sanding bar
• Sandpaper (coarse)
• Covering Iron (HAN101)
• Dental floss or string
Additional Required Tools and Adhesives
Warning

5
Before beginning the assembly of the Extra 260, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact
the place of purchase.
If you find any wrinkles in the covering, use a heat gun or covering iron to remove them. Use caution while
working around areas where the colors overlap to prevent separating the colors.
Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date
of purchase. This warranty does not cover any parts damaged by use or modification. In no case shall Horizon
Hobby's liability exceed the original cost of the purchased kit. Further, Horizon Hobby reserves the right to
change or modify this warranty without notice.
In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability
shall be assumed nor accepted for any damage of the final user-assembled product. By the act of using the
product, the user accepts all resulting liability.
Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any
warranty question that you have. Please do not contact your local hobby shop regarding warranty issues, even if
that is where you purchased it. This will enable Horizon to better answer your questions and service you in the
event that you may need any assistance.
If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to
return this kit immediately in new and unused condition to the place of purchase.
Horizon Hobby
4105 Fieldstone Road
Champaign, Illinois 61822
[phone]
www.horizonhobby.com
The servos used for the control surfaces of the Extra 260 must have a minimum of 80 ounce inch of
servo torque. In the prototype Extras, we used JR8231 and JR9411 servos. On the rudder we used one
JR8411SA servo.
This manual is divided into sections to help make assembly easier to understand and to provide breaks between
each major section. Remember to take your time and follow the directions.
Before Starting Assembly
Warranty Information
Servo Selection
Using the Manual

6
Required Parts
• Elevator (left and right) • Fuselage
• Rudder • Hinges (17)
• Wing panel (right and left)
• Aileron (left and right)
• Stabilizer (left and right)
Required Tools and Adhesives
• 30-minute epoxy • Syringe
• Sandpaper (coarse) • Toothpicks
• Pacer Hinge Glue (PT-55)
• Razor saw • Petroleum jelly
Properly hinging the control surfaces on giant-scale
models is vitally important. Poorly installed hinges
affect the model’s precision and control response
and can also be dangerous. Each and every hinge
needs to be securely bonded in place in both the
flying surface and the control surface. The hinge pivot
points need to be exactly parallel to each other and
precisely located on the center of the hinge line.
   Step 1
Sand each end of the hinge point hinge using coarse
sandpaper. This will improve the bond of the epoxy
to the hinge. Apply a thin coat of Petroleum jelly to
the hinge point to prevent the epoxy from gluing the
hinge surface.
   Step 2
Mix 1 ounce of 30-minute epoxy. Using a glue
syringe or toothpick, place a sufficient amount of
30-minute epoxy into one of the hinge pockets in
the aileron leading edge only. Install one of the
hinge points until the hinge pin center is flush with
the leading edge of the aileron. Some epoxy should
ooze out of the pocket as the hinge is installed. If
not, remove the hinge and apply more epoxy. After
gluing a few hinges, you’ll get the hang of just how
much epoxy is needed. Wipe away any excess epoxy
with rubbing alcohol. Recheck that the center of the
hinge pin is flush and parallel with the leading edge.
Continue installing hinges in the leading edge of
the aileron. The control surfaces (ailerons) will be
installed after the epoxy is fully cured.
Note: Be sure that the hinge pivot pins are
parallel and flush to the aileron leading edge.
It’s important to frequently mix a fresh batch
of 30-minute epoxy in order to achieve good
glue joint penetration. If you notice the epoxy
becoming thicker, then mix a new batch.
Hint: You can also use Pacer PT-55
Hinge Glue to glue the hinges. Follow the
instructions here as well as on the glue bottle
to achieve the best results.
Section 1 – Hinging the Control Surfaces

7
   Step 3
Allow the glue to fully cure for at least 6 hours.
When cured, work each hinge throughout its full
motion several times using your hands. This will
break free any epoxy that may have found its way into
the hinge joint. Move the hinge throughout its full
travel until no resistance is felt. This may take
as many as 40 or 50 times.
   Step 4
Mix 1 ounce of 30-minute epoxy or use Pacer PT-55
hinge glue. Place a sufficient amount of glue in each
of the hinge pockets in one wing panel.
   Step 5
Carefully attach the aileron to the wing, making sure
the hinges are inserted in their respective hinge
pockets. Press the aileron and wing together such
that less than a 1/64" hinge line gap exists between
the aileron and wing. The bevels should virtually
touch. Use a paper towel and rubbing alcohol to wipe
away any visible epoxy around the hinges.
   Step 6
Double-check the hinge gap and allow the glue to
fully cure for at least 6 hours.
   Step 7
When fully cured, move each control surface
throughout its travel range several times to break
away any epoxy in the hinge. Be sure to deflect the
surface fully.
Section 1 – Hinging the Control Surfaces

8
  Step 8
Use a razor saw to cut off the first section of one of
the hinges. This is done to clear the tube installed
in the stabilizer.
  Step 9
Glue the elevator hinges in place using the same
techniques used to hinge the ailerons. The
shortened hinge will be installed into the stabilizer
towards the root.
 Step 10
Repeat Steps 1 through 9 for the remaining aileron
and elevator.
Hint: Combining the left and right wing/
aileron and/or left and right stabilizer/elevator
while waiting for glue to cure will make this
section move along much quicker.
 Step 11
Since all that’s left is the rudder, this is a good time to
glue it as well. Follow Steps 1 through 7 to complete
hinging the control surfaces.
Section 1 – Hinging the Control Surfaces

9
Required Parts
• Wing panel w/aileron (right and left)
• Stabilizer w/elevator (left and right)
Required Tools and Adhesives
• Straight edge/ruler • Felt-tipped pen
• Scissors • Hobby knife w/#11 blade
• Covering Iron (HAN101)
• Clear UltraCote® (HANU964)
It is a good idea to be sure that the aileron and
elevator hinge lines be sealed airtight Sealing the
hinge line has several advantages. A sealed hinge line
gives a greater control response for a given control
deflection. It also offers more precise, consistent
control response and makes trimming easier.
Sealing the aileron and elevator hinge line is highly
recommended. Failure to do so may cause control
surface flutter, resulting in a crash.
   Step 1
Cut a piece of Clear UltraCote® for sealing the
ailerons to approximately 1" x 32". Fold the UltraCote
down the center with the adhesive side to the outside
making a sharp crease at the fold.
   Step 2
Remove the backing from the UltraCote. Place the
folded crease side into the center of the hinge line
on the bottom of the wing. Using a straight edge as
shown, hold one side of the covering in place while
ironing down the opposite side with a sealing iron.
We recommend setting the iron temperature to 320°
for this procedure.
   Step 3
Fully deflect the aileron in the up position. Place
the straight edge over the hinge line covering that
you just ironed down in Step 2 with the edge of the
straight edge placed firmly at the bottom of the hinge
line as shown. Iron down this side of the covering,
making sure the aileron is fully deflected.
 Step 4
Repeat Steps 1 through 3 for the remaining aileron
hinge gap.
 Step 5
Repeat Steps 1 through 3 for both elevator halves
using a 1" x 15" piece of clear covering.
Section 2 – Sealing the Hinge Gaps

10
Required Parts
• Wing panel (right and left)
• 3 1/2" aileron linkage (2)
• 8-32 x 2 1/4" control horn screw (2)
• 8-32 flange nut (2)
• Molded swivel link (2)
• Ball link for swivel link (2)
• 4-40 x 1/2" socket head screw (2)
• 4-40 lock nut (2)
• Ball link for servo arm (2)
Required Tools and Adhesives
• Drill • Drill bit: 1/16"
• Ruler
• Phillips screwdriver (small)
• 12" Servo Extension (JRPA098) (2)
• 3D 1/2 Servo Arm 4-40: JR (HAN3578) (2)
  Step 1
Install the servo hardware (grommets and eyelets)
included with the servo.
  Step 2
Plug a 12" servo extension onto the servo. Either
tie the servo leads together, using a commercially
available connector, or use unwaxed dental floss to
secure the extensions to prevent them from coming
loose during flight.
  Step 3
Tie a weight to a piece of string. A wheel collar works
great in this application. Lower the string into the
wing from the aileron servo opening. Hold the wing
with the tip upwards and let the weight drop out
through the wing root for the servo.
Section 3 – Aileron Servo Installation