Phoenix Model Extra 300 S User manual

Instruction Manual
Wingspan : 1900mm (74.8 inch)
Length :
1720mm (67.7 inch)
Weight : 5100g - 5600g
Engine : 160 two stroke
Radio : 6 channel/ 5 high torque servo
and 1standard servo
g

MAIN GEAR ASSEMBLY
(2) Main gear aluminum
(2) 75mm diameter wheel
(2) Fiberglass wheel pant
(4) 4mm x 20mm socket head screw
(4) 8mm flat washer
(4) 4mm lock washer
(2) 16mm flat washer
(2) 8mm nut
(4) Collar
(4) 3mm x 4mm screw
(2) 4mm x 85mm axle
TAIL WHEEL ASSEMBLY
(1) Tail wheel bracket w/ wire
(1) 35mm diameter wheel
(2) 3mm collar
(2) 3mm screw
(2) Nylon control clasp
(3) 3mm x 12mm wood screw
ELEVATOR CONTROL SYSTEM
(1) 3mm x 170mm metal pushrod
(1) 3mm x 95mm metal pushrod
(2) M3 clevis
(2) 3mm x 50mm screw
(2) Set aluminum control horn
(2) Nylon horn
(2) Nylon ball link
(2) Aluminum ball
(2) 3mm x 12mm screw
(2) 6mm flat washer
(2) 3mm nut
1
KIT CONTENTS: We have organized the parts as they come out of the box for better identification
during assembly. We recommend that you regroup the parts in the same manner. This will ensure you
have all of parts required before you begin assembly.
KIT CONTENTS
THROTTLE CONTROL SYSTEM
(1) 1.3mm x 600mm wire
(1) 3.5mm x 350mm nylon
pushrod housing
(1) Metal connector
(1) 4mm x 4mm machine screw
FUEL TANK
(1) Nylon fuel Tank
(1) Metal clunk
(1) Pre - assembled stopper w / 3 tube
MISCELLANEOUS ITEMS
(1) 32mm x 680mm diameter
aluminum dihedral
(4) 6mm x 45mm nylon screw
(4) 2.6mm x 10mm wood screw
(2) 4mm x 30mm nylon screw
(2) 4mm x 35mm screw
(2) 8mm flat washer
(2) Plastic lock wing
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Instruction Manual
RUDDER CONTROL SYSTEM
(1) 3mm x 120mm Metal pushrod
(1) M3 Clevis
(1) 3mm x 50mm screw
(1) Set aluminum control horn
(1) Nylon horn
(1) Nylon ball link
(1) Aluminum ball
(1) 3mm x 12mm screw
(1) 6mm flat washer
(1) 3mm nut
AILERON CONTROL SYSTEM
(2) 3mm x 95mm metal pushrod
(2) M3 Clevis
(2) 3mm x 50mm screw
(2) Set aluminum control horn
(2) Nylon horn
(2) Nylon ball link
(2) Aluminum ball
(2) 3mm x 12mm screw
(2) 6mm flat washer
(2) 3mm nut
MOTOR MOUNT ASSEMBLY
(4) 4mm x 25mm screw
(4) 4mm lock washer
(4) 8mm flat washer
(4) 4mm x 30mm screw
(4) 4mm lock washer
(8) 4mm nut
(2) Engine mount

TOOLS AND SUPPLIES NEEDED
• Medium C/A glue
• 30 minute epoxy
• 6 minute epoxy
• Hand or electric drill
• Assorted drill bits
• Modeling knife
• Straight edge ruler
SUGGESTION
To avoid scratching your new airplane, do not unwrap
the pieces until they are needed for assembly. Cover
your workbench with an old towel or brown paper,
both to protect the aircraft and to protect the table.
Keep a couple of jars or bowls handy to hold the
small parts after you open the bag.
NOTE:
1. Please trial fit all the parts. Make sure you have
the correct parts and that they fit and are aligned
properly before gluing! This will assure proper
assembly. The EXTRA 300S is hand made from
natural materials, every plane is unique and
minor adjustments may have to be made.
However, you should find the fit superior and
assembly simple.
2. The painted and plastic parts used in this kit are
fuel proof. However, they are not tolerant of many
harsh chemicals including the following: paint
thinner, C/A glue accelerator, C/A glue debonder
and acetone. Do not let these chemicals come in
contact with the colors on the covering and the
plastic parts.
3. The EXTRA 300S will perform 3-D aerobatics
easily if you use the largest engines
recommended within the engine range. If you
setup your airplane to do 3D maneuvers, you
will need to be throttle conscious; that is,
never apply full throttle on straight and level
flying or in dives to prevent flutter.
SAFETY PRECAUTION:
• This is not a toy.
• Be sure that no other flyers are using your radio
frequency.
• Do not smoke near fuel.
• Store fuel in a cool, dry place, away from
children and pets.
• Wear safety glasses.
• The glow plug clip must be securely attached to
the glow plug.
• Do not flip the propeller with your fingers.
• Keep loose clothing and wires away from the propeller.
PREPARATIONS
Remove the tape and separate the ailerons
from the wing and the elevators from the stab.
Use a covering iron with a covering sock on
high heat to tighten the covering if necessary.
Apply pressure over sheeted areas to
thoroughly bond the covering to the wood.
• Do not start the engine if people are near. Do not
stand in line with the side of the propeller.
• Make engine adjustments from behind the propeller
only. Do not reach around the spinning propeller.
INSTALLING THE AILERONS
1. Drill a 2.4mm hole, 13mm deep in the center of
each hinge slot to allow the CA to “wick” in. Use
the modeling knife to clean out the slots.
2. Use the modeling knife to cut a strip of covering
from the hinge slots in the wing and aileron.
3. Locate the four CA hinge strip. Snip off the
corners so they go in easier.
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Instruction Manual
CUT THE COVERING
AWAY FROM THE SLOT
DRILL A HOLE
DEEP, IN CENTER
OF HINGE SLOT
1
• 2 bender plier
• Wire cutters
• Masking tape
• Thread lock
• Paper towels
• Rubbing alcohol

5. Tie the string from inside the wing to the end of
the servo wire. Pull the servo wire through the
wing with the string. Tape the servo wire to the
wing to prevent it from falling back into the wing.
5
TEMPORARY PIN
TO KEEP HINGE
CENTERED
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Instruction Manual
3
Remove the
covering
2
CA glue
4
Collar
6
Masking tape
4. Test fit the ailerons to the wing with the hinges.
If the hinges don’t remain centered, stick a pin
through the middle of the hinge to hold it in
position.
5. Remove any pins you may have inserted into
the hinges. Adjust the aileron so there is a
small gap between the LE of the aileron and
the wing. The gap should be small, just enough
to see light through or to slip a piece of paper
through.
6. Apply six drops of thin CA to the top and bottom
of each hinge. Do not use CA accelerator. After
the CA has fully hardened, test the hinges by
pulling on the aileron.
INSTALL THE AILERONS SERVOS & PUSHRODS
1. Install the servo in the wing require the use of
one 305mm servo extension for each aileron
servo. One Y-harness connector is required
and is used to allow the aileron servo to plug
into one slot in your receiver. You may have a
computer radio that allows you to plug the
servos into separate slots and then mix them
together through the radio transmitter. If you
choose to mix them with the radio rather than
the Y-harness, refer to the instructions with
your particular brand of radio.
2. Attach the servo extension to the aileron servo.
Secure the connectors together using a large
piece of heat shrink tubing, tape or other
method for securing the connectors together.
3. Turn the wing panel right side up. Using a
modeling knife, remove the covering from over
the precut servo box.
4. Using the string as a guide and pass the string from
the servo opening to the hole in the root of the wing.
Note: A weigh tied to a string can be used first,
then tied to the servo lead to pull it through.

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9
↑
WING TIP
6. Temporarily position the aileron servo into the
servo bay. Drill a 1.6mm hole through the four
mounting holes of the servo, drilling through the
plywood mounting plate in the wing. Install and
remove a servo mounting screw into each of the
four holes. Insert a drop of thin CA into the
holes to harden the wood. After the glue has
cured, install the servo into the servo bay using
the hardware that came with your servo. Center
the servo and install a servo arm as shown.
7. Repeat step # 1 - # 6 to install the second
aileron servo in the opposite wing half.
3. Repeat step # 1 - # 2 to install the control horn
on the second aileron.
INSTALLING THE AILERON LINKAGES
The aileron linkages are assembled as shown
below.
1. Locate the pushrod wire. Slide a silicon clevis
retainer onto a clevis. Screw a M3 nut and a
threaded metal clevis onto the threaded end of
the wire. Tighten the nut against the clevis and
then install the clevis on the aileron control
horn.
INSTALLING THE CONTROL HORNS
1. The aileron has a block wood plate for mounting
the control horn. One aileron control horn in
positioned on each aileron. Using a ruler and a
pen, locate and mark the location of the control
horn. It should be mounted on the bottom side
of the aileron at the leading edge, in line with
the aileron pushrod.
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2. Drill through the mark you made with a (3mm)
drill bit. Hard the hole with thin CA. Install the
control horn. Remember use thread locking
compound to secure.
Note: The hole on the nylon horn is aligned
with the hinge line and pushrod is aligned with
the servo arm.
10
M3 nut
M3 clevis
95mm
22mm 22mm
Aluminum washer
Aluminum control
Plastic horn 3mm Screw
RIGHT WRONG
8
IN LINE
↑
WING TIP
↑
WING TIP

5. Repeat step 1 - step 3 for the second aileron
linkage.
2. Make the same way for the plastic linkball to the
other side of the pushrod wire.
3. Plug the aileron servo into the receiver and
center the servo. Install the servo arm onto the
servo. The servo arm should be perpendicular
to the servo and point toward the middle of the
wing.
4. Center the aileron and hold it in place using a
couple of pieces of masking tape. Adjust the
linkage until the aileron and the servo arm are
both centered and then tighten the nut against
the clevis. Install the plastic linkball to the servo
arm. Remember use thread locking compound
to secure.
INSTALLING THE HORIZONTAL STABILIZER
1. Using a modeling knife, cut away the covering from
the fuselage for the stabilizer and remove it.
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3. Check the fit of the horizontal stabilizer in its
slot. Make sure the horizontal stabilizer is
square and centered to the fuselage by taking
measurements, but don't glue anything yet.
4. With the horizontal stabilizer correctly aligned,
mark the shape of the fuselage onto the bottom
and into the top of the horizontal stabilizer
using a water soluble/ non-permanent felt-tip
pen.
2. Draw a center line onto the horizontal stabilizer
and slide it into the fuselage.
15
11
Adjust
the linkages
12
Link ball
M3 nut
M3 clevis

9. After the epoxy has fully cured, remove the
masking tape or T-pins used to hold the
stabilizer in place and carefully inspect the glue
joints. Use more epoxy to fill in any gaps that
were not filled previously and clean up the
excess using a paper towel and rubbing alcohol.
10. Repeat step 1 - step 6 from the installing
aileron for the installing elevator.
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21
INSTALLING THE RUDDER
Repeat step 1 - step 6 from the installing aileron
for the installing elevator.
5. Remove the stabilizer. Using the lines you just
drew as a guide, carefully remove the covering
from between them using a modeling knife.
When cutting through the covering to remove it,
cut with only enough pressure to only cut
through the covering it's self. Cutting into the
balsa structure may weaken it. This could lead
to possible failure during flight.
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Instruction Manual
6. Attach the wing to the fuselage as picture.
7. Test the position of the elevator and adjust it as
shown.
8. When you are sure that everything is aligned
correctly, mix up a generous amount of 30
minute epoxy. Apply a thin layer to the bottom
of the stabilizer mounting area and to the stabilizer
mounting platform sides in the fuselage. Insert
the stabilizer in place and re-align. Double
check all of your measurements one more time
before the epoxy cures. Remove any excess
epoxy using a paper towel and rubbing alcohol
and hold the stabilizer in place with T-pins or
masking tape.
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18
Plastic Screw

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Instruction Manual
INSTALLING THE MAIN LANDING GEAR
1. Nuts have been installed at the factory.
2. Install main landing gear into the fuselage using
(4) 4mm x 20mm socket head screws and flat
washers provided in the kit.
2. Set the tail wheel assembly in place on the
plywood plate.
3. Drill 2,6mm pilot holes through the plywood
plate.
4. Secure the tail wheel bracket in place using two
3mm x 12mm screw.
5. Align the tail wheel wire so that the wire is
parallel with the bottom of the rudder.
INSTALLING THE TAIL WHEEL
1. Using the knife cut away the wood from the
bottom of the rudder and slide the two nylon
clasps into the slot. Using C.A glue the nylon
clasps as shown.
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26
Wheel
Collar

INSTALLING THE WHEEL PANTS
1. Locate the wheel pants from the hardware bag.
Mark the locations of the mounting axles onto
the wheel pants. The locations of the two
mounting holes are the middle of the wheel
opening, on right side, left side and 10mm from
the bottom of the wheel pant.
2. Using a 5mm drill bit, carefully drill two pilot
holes through the wheel pant at the TWO
marks you made.
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!
3. Using a modeling knife, carefully cut out two
line from the margin of the hole onto the wheel
pant. Just cut only one side of the wheel pant,
where the main gear will install. Be sure to
make a left and right wheel pant.
4. Slide a 4.5mm nut/ three 16mm flat washers/
4.5mm nut/ collar/ wheel/ collar onto the axle.
5. Slide the axle assembly into the wheel pant.
There are just one nut and two flat washers
outside of the wheel pant.
6. Remove one nut, one flat washer. Attach the
main landing gear to the axle.
7. Center both collars and wheel in the middle of
the wheel pant, lock both collars in place using
a hexagon 2mm screw.
8. With the landing gear in place, tighten two nuts.
Drill
Cut
30
After installing the wheel pant, apply a small
drop of thin C/A to the bottom nut.
9. Repeat step # 1-8 to install the second wheel
pant assembly.
INSTALLING THE THROTTLE PUSHROD HOUSING
1. Place the engine into the engine mount and
align it properly with the front of the cowling.
The distance from the firewall to the front of the
engine thrust washer should [135mm]
If your engine is equipped with a remote needle
valve, we suggest installing it into the engine at
this time.
2. When satisfied with the alignment of the engine,
use a pencil and mark the mounting hole
location onto the firewall, where the throttle
pushrod will exit.
3. Now, remove the engine. Using a 5mm drill bit,
drill holes through the firewall and the forward
bulkhead at the marks made.
4. Slide the pushrod housing through the hole in
the firewall, through the hole in the forward
bulkhead, and into the servo compartment.
5. Apply a couple of drops of thin C/A to the pushrod
housing where it exits the firewall and where it
passes through the forward bulkhead. This will
secure the housing in place.
6. Using a modeling knife, cut off the nylon
pushrod housing in front of the servo tray.
16 mm flat washer
31
!
!

3. Carefully bend the second nylon tube up at a 45
degree angle (using a cigarette lighter). This
tube will be the vent tube to the muffler.
4. Carefully bend the third nylon tube down at a 45
degree angle (using a cigarette lighter). This
tube will be vent tube to the fueling valve
When the stopper assembly is installed in the
tank, the top of the vent tube should rest just
below the top surface of the tank. It should not
touch the top of the tank.
5. Test fit the stopper assembly into the tank. It
may be necessary to remove some of the
flashing around the tank opening using a
modeling knife. If flashing is present, make sure
none of it falls into the tank.
6. When satisfied with the alignment of the stopper
assembly tighten the 3mm x 20mm machine
screw until the rubber stopper expands and
seals the tank opening. Do not over tighten the
assembly as this could cause the tank to split.
7. Using a modeling knife, cut 3 lengths of fuel line
150mm long. Connect 2 lines to the 2 vent tubes
and 1 line to the fuel pickup tube in the stopper.
8. Feed three lines through the fuel tank
compartment and through the pre-drilled hole in
the firewall. Pull the lines out from behind the
engine, while guiding the fuel tank into place.
Push the fuel tank as far forward as possible,
the front of the tank should just about touch the
back of the firewall. Blow through one of the
lines to ensure the fuel lines have not become
kinked inside the fuel tank compartment. Air
should flow through easily.
Do not secure the tank into place permanently
until after balancing the airplane. You may need
to remove the tank to mount the battery in the
fuel tank compartment.
9. To secure the fuel tank in place, apply a bead of
silicon sealer to the forward area of the tank,
where it exits the fuselage behind the engine
mounting box and to the rear of the tank at the
forward bulkhead.
10. Use 6mm x 8mm hardwood to secure the fuel
tank in place by CA glue.
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Instruction Manual
INSTALLING THE ENGINE
This manual, we used the OS 160 - two stroke
1. Install the engine mount.
2. Locate the long piece of wire used for the
throttle pushrod. One end of the wire has been
pre-bend in to a "Z" bend at the factory. This
"Z" bend should be inserted into the throttle
arm of the engine when the engine is fitted
onto the engine mount. Fit the engine to the
engine mount using the screws provided.
10down thrust
30right thrust
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INSTALLING THE STOPPER ASSEMBLY
1. The stopper has been pre-assembled at the factory.
2. Using a modeling knife, cut one length of silicon
fuel line (the length of silicon fuel line is
calculated by how the weighted clunk should
rest about 8mm away from the rear of the tank
and move freely inside the tank). Connect one
end of the line to the weighted clunk and the
other end to the nylon pick up tube in the
stopper.
!
!!
135mm