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

11
  Step 4
Tie the string to the servo extension and insert the
servo into the wing. Use the string to pull the servo
lead through the wing. Position the servo so the
output shaft is towards the trailing edge of the wing.
Use a 1/16" drill bit to drill the locations for the
servo screws. Mount the servos using the hardware
provided with the servos.
  Step 5
Mix a small amount of 30-minute epoxy and lightly
coat the inside of the hole in the aileron and the
8-32 x 2 1/4" control horn screw. Thread the screw
into the hole from the top of the surface. Wipe away
any excess epoxy on the wing and screw with rubbing
alcohol and a paper towel. Screw the 8-32 flange nut
in place as shown. Allow the epoxy to fully cure.
  Step 6
Screw the molded swivel link onto the 8-32 screw
until the distance from the aileron surface to the top
of the link is 13/16".
Section 3 – Aileron Servo Installation

12
  Step 7
Using the 4-40 screws (don’t substitute a standard
screw) and nuts included, attach the ball link to
the outer hole in the servo arm from the bottom
side as shown. The sequence is screw, ball link,
servo arm and nut. Don’t forget to use threadlock.
Note: Hangar 9® aluminum servo arms
are suggested for ease of installation and
durability. Use 3D 1/2 Servo Arm 4-40: JR
(HAN3578) for the aileron servos.
  Step 8
Screw a 4-40 ball link 5 to 6 turns onto each end of
a 3 1/2" long aileron linkage. Adjust the linkage length
until the hole in the ball link aligns with the outer
hole in the servo arm when the aileron is neutral and
the servo arm is centered.
  Step 9
Center the servo using the radio system. Attach the
servo horn to the servo using the screw provided with
the servo.
  Step 10
Attach the linkage to the servo horn on the aileron.
Adjust the link so the aileron is centered at the same
time as the servo.
 Step 11
Repeat Steps 1 through 11 for the remaining
wing panel.
Section 3 – Aileron Servo Installation

13
Required Parts
• Wing panels • Fuselage
• Wing tube • Stabilizer tube
• 1/4-20 x 2" nylon bolt (2)
• 4-40 x 1/2" socket head screw (2)
 Step 1
Remove the two 4-40 x1/2" screws securing the hatch
to the fuselage. Remove the hatch and store it in a
safe place until later.
 Step 2
Locate the wing tube and carefully slide it into one
wing panel. Slide the wing (with tube) into the wing
tube opening in the fuselage. Make sure the wing
panel alignment pins slide into the holes provided
in the fuselage. Be sure the alignment pins are
secure in the wing halves before installing the wings.
If they are not, remove the pin and apply a small
amount of thin CA into the tube socket and reinstall
the alignment pin.
 Step 3
Carefully slide the remaining wing panel onto the
wing tube that projects from the fuselage. The fit may
be tight; use caution when inserting the wing panels
onto the wing tube and fuselage.
 Step 4
Secure the wing panels using the 1/4-20 x 2" nylon
wing bolts.
 Step 5
Insert the stabilizer tube into the aft hole in the
fuselage. Measure the distance of the exposed tube
and adjust until both sides are equal.
Section 4 – Wing and Stabilizer Installation

14
 Step 6
Mark the tube on both sides of the fuselage using a
felt-tipped pen.
 Step 7
Remove the tube and install it into one elevator
up to the first line on the tube. Drill through the hole
into the stabilizer and tap for a 4-40 bolt. Install a
4-40 x 1/2" bolt to secure the tube in the stabilizer.
 Step 8
Slide the assembly into the fuselage. Slide the
remaining stab half onto the tube and drill and tap the
location for the 4-40 retaining bolt. Install the bolt to
complete the procedure.
Hint: When removing the stabilizer for storage,
remove only one bolt, leaving the tube secured
in the remaining stabilizer. Trying to install the
tube without the aid of an alignment guide can
be frustrating.
Section 4 – Wing and Stabilizer Installation

15
Required Parts
• Fuselage w/stabilizer
• 5 1/2" elevator linkage (2)
• 8-32 x 21/4" 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”
• 5” 4-40 linkage (2) • Dental floss or string
• Aluminum servo arms (2)
• Control horn ball ends (2)
• 18” Servo Extensions (JRPA099) (2)
Note: Using two standard rotation servos and
a standard “Y” harness for the elevators will
result in them moving in opposite directions
instead of the same direction. As such, the
elevator installation will either require the
use of one reversed rotation servo and one
standard rotation servo or a reversing “Y”
harness. It is highly recommended to use a
computer radio or a JR® MatchBox™ to link
the two elevator servos to operate properly.
The elevators require a minimum of 80 ounce inch of
servo torque. In the prototype Extras we used JR8231
and JR9411 servos with excellent results. Using
servos with less torque could cause a crash.
  Step 1
Install an 18" servo extension onto an elevator
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. Install one side
only of the two Y-harnesses to two of the servos,
also tying knots to prevent disconnection. The other
two servos will be hooked up to the Y-harness when
installed in the airplane. One elevator servo will need
to be a reversed-direction servo.
  Step 2
Install the servo in the fuselage tail section with the
output shaft to the rear as shown in the photo.
  Step 3
Drill a 1/16" pilot hole before installing the screws.
Using the screws included with the servos, fasten the
servos in place.
  Step 4
Mix a small amount of 30-minute epoxy and lightly
coat the inside of the hole in the elevator and the
8-32 x 2 1/4" control horn screw. Thread the screw
into the hole from the top of the elevator. Wipe away
any excess epoxy on the wing and screw with rubbing
alcohol and a paper towel. Screw the 8-32 flange nut
in place as shown. Allow the epoxy to fully cure.
Section 5 – Elevator Servo Installation

16
  Step 5
Screw the molded swivel link onto the 8-32 screw
until the distance from the elevator surface to the top
of the link is 1 1/8".
  Step 6
Remove the stock servo arms from the elevator
servos and replace them with 3D XL 1/2 servo arms.
The arms need to face down as shown. Be sure to use
a drop of threadlock on the servo arm screw if using
metal-geared servos.
  Step 7
Screw a 4-40 ball link 5 to 6 turns onto a 5 1/2"
elevator linkage. Screw the opposite end of the
linkage into the swivel control horn on the elevator.
Adjust the linkage length until the hole in the ball link
lines up with the outer hole in the servo arm when the
elevator is neutral and the servo arm is centered.
  Step 8
Use the included 4-40 screws and nuts to attach
the ball link to the outer hole in the arm. From the
topside, the correct sequence is 4-40 screw, ball
link, servo arm and 4-40 locknut. Be sure to use
threadlock.
Step 9
Repeat Steps 1 through 8 for the remaining elevator
servo and linkage.
Section 5 – Elevator Servo Installation

17
Required Parts
• Fuselage • Wheel pant (left and right)
• #8 washer (4) • 8-32 nylon lock nut (4)
• 3 1/4" Wheel (2) • 3/16" wheel collar (4)
• #4 washer (2)
• 8-32 x 3/4" socket head bolt (4)
• 4-40 x 1/2" socket head screw (2)
Required Tools and Adhesives
• 5/32" hex wrench • Ruler
• Felt-tipped pen • Square
• Adjustable wrench (small)
 Step 1
Install the axles in the landing gear. Secure the axles
using an adjustable wrench and the nuts provided
with the axles.
 Step 2
Install the landing gear using four 8-32 x 3/4" socket
head bolts, four #8 washers and four 8-32 nylon lock
nuts. (The lock nuts are placed inside the fuselage.)
  Step 3
Fit the pants over the axle on the landing gear. Align
the centerline of the wheel pant to the centerline of
the fuselage. Use a felt-tipped pen to transfer the
location of the hole onto the pant.
  Step 4
Remove the pant and use a 9/64" drill bit to drill the
location marked in the previous step.
Section 6 – Landing Gear Installation

18
  Step 5
Install a 4-40 blind nut into the hole from the inside
of the pant. The nut will be drawn into the plywood
later in this section.
  Step 6
Install the following items onto the axle: wheel pant,
3/16" wheel collar, wheel then another 3/16" wheel
collar. It will be necessary to fit the parts inside the
wheel pant and slide them onto the axle.
  Step 7
Secure the pant in place using a 4-40 x 1/2" socket
head screw and #4 washer. Use threadlock on the
screw to prevent it from coming loose in flight.
  Step 8
Center the wheel in the wheel pant and tighten the
collars to prevent the wheel from moving side to side.
Use threadlock on both set screws.
 Step 9
Repeat Steps 3 through 8 for the remaining
wheel pant.
Section 6 – Landing Gear Installation

19
Required Parts
• Fuselage • Engine mount (2)
• 8-32 x 1" screw (4) • 8-32 locknut (4)
• #8 washer (8) • 17" throttle pushrod tube
• 8-32 blind nut (4) • Nylon clevis
• 1/4" fuel tubing
• 8-32 x 1 1/2" socket head bolt (4)
• 9/16" x 13/16" x 2 3/4" hardwood block (2)
Required Tools and Adhesives
• Medium CA • Square
• Drill • Drill bit: 3/16", 7/32"
• Ruler
 Step 1
Locate the right and left engine mounts and the two
9/16" x 13/16" x 2 3/4" hardwood blocks. Position an
engine mount onto the narrow edge of a block. Mark
the locations for the mounting bolts onto
the block.
 Step 2
Use a 3/16" drill and drill press to drill the two holes
through the blocks.
 Step 3
Temporarily attach the engine to the engine mount
using four 8-32 x 1" screws, four 8-32 locknuts and
four #8 washers. Position the arrows on the mounts
so they face towards the head of the engine.
 Step 4
Position the engine on the mounts so the face of the
drive washer is 6 1/16" from the work surface. Use
a square to make sure the engine is square to the
engine mounts.
Section 7A – Engine Installation: Saito

20
 Step 5
Measure and record the measurements as shown.
Hint: A Saito™ 1.80 should be 2 3/8" between
the mounts. The distance from the centers on
the mounts is 2".
 Step 6
Mark the centerline for the engine onto the firewall.
Note the vertical centerline is offset to the right side
of center as viewed from the front due to the built-in
right-thrust. Mark the positions for the mount halves
as shown. These will be the same no matter what
engine if you are using the supplied mount.
Note: The engine is not centered between the
engine mount holes. The lines drawn for the
mount reflect this.
 Step 7
Take the measurement from Step 5 and divide it
by two. (For the Saito, this will be 1 3/16".) Use this
measurement to mark the positions above and below
the centerline for the engine mount.
 Step 8
Use a drill and a 7/32" drill bit to drill four holes at
the intersections of the lines drawn for the engine
mount bolts.
Section 7A – Engine Installation: Saito