AeroWorks Extra 260 User Manual

1 50cc EXTRA 260 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS 401 Laredo Unit “D”, Aurora, CO. 80011 - Phone 303-366-4205 - Fax 303-366-4203

10 1. In order to complete this step you will need: Clear covering, Covering Iron, Scissors, Rubbing Alcohol, and Paper towel. Applyi

11 5. Cut the covering even with the wing tip being careful not to cut it to short. 6. Save the excess covering from both wings in order to seal

12 9. Using the same method as step 8 tack the cover-ing to the tip of the wing once again keeping it centered on the leading edge. 10. Once the

13 Aileron Servo Installation 1. The ailerons have been pre-hinged and glued to the wing panels and are ready for flight. No other steps are neces

14 5. Draw the 18” servo extension through the wing and pull through the wing root rib. 6. Install servo in servo well with the output arm toward

15 9. Aileron servo mounted in bottom of wing. Aileron Control Linkage Installation 1. Gather the aileron control linkage parts as shown below. 1

16 4. Use a drop of thick CA glue on each screw as shown. 5. Securely fasten the control horn to the aileron with six wood screws as shown. 6. Ta

17 Elevator Servo Installation 1. The elevators have been pre-hinged and glued to the stabs and are ready for flight. No other steps are necessary

18 5. Install servo in servo cut out with the output shaft toward the nose and mark locations of servo mounting holes. 6. Remove servo and use a

19 2. Assemble two pushrod and control horn as-semblies with servo output arms as shown. The ball link goes between the left and right sides of the

2 TABLE OF CONTENTS Page Aeroworks Contact Information ………………………………………………………………. 3 Introduction ……………………………………………………………………………………

20 7. Tape leading edge of the elevator balance tab to the leading edge of the stab in the neutral position. Plug the elevator servo into the re-c

21 Rudder Installation 1. Gather the rudder, four hinges, rubbing alco-hol, petroleum jelly and epoxy materials as shown. Use 15-30 minute epoxy to

22 5. Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre-drilled holes in the leading edge of the rudder. Apply epox

23 2. Install the rudder servo in the forward servo cut-out with the output shaft to the rear. Your model may only have one rudder servo cut out.

24 2. Gather the rudder control linkage parts shown below. 2 Rudder cables, 2 threaded metal RC links, 4 threaded couplers, and 4 brass swag-ing t

25 6. Loop the cable back through the brass swage tube as shown. 7. Tighten the second loop through the brass swage tube and crimp the brass tub

26 10. A drop of thin CA may be applied to the swage tube to help secure the cable. Attach a metal threaded RC link to the threaded cou-pler. 1

27 3. Use a drop of thick CA glue on each screw as shown. 4. Mount rudder control horns using six wood screws. 5. Repeat the above steps for

28 8. Remove ball links from the rudder control horns. Attach two threaded couplers to ball links as shown. Thread couplers halfway into ball links

29 12. Tighten the second loop through the brass swage tube as shown. 13. Crimp the brass tube with a crimping tool or pliers. 14. Cut off exce

3 401 Laredo Unit D Aurora, CO 80011 Phone: (303) 366-4205 Fax: (303) 366-4203 Website: www.aero-works.net E-mail: [email protected] Thank

30 16. Re-attach ball link to rudder control horn on both sides of the rudder. 17. With radio on, and rudder centered, adjust rud-der pull-pull

31 3. Mount the tail wheel steering tiller using two wood screws. 4. Place the tail wheel leaf spring on top of the tail wheel strut. Position th

32 7. Use pliers to twist spring ends closed around the tillers after desired tension and direction adjustments are complete. 8. Tail wheel final

33 Main Landing Gear Installation 1. Gather the landing gear parts as shown below. Landing gear strut, 4 mounting bolts, washers, and lock washers

34 5. Note that the trailing edge of the landing gear strut is tapered. The tapered edge goes toward the rear of the fuse. 6. Use a drop of blu

35 9. Use a drop of blue Loctite and reinstall the landing gear cover screws. Wheels and Wheel Pants Installation 1. Gather the wheels, axles, an

36 4. Align the flat sides of the axle bolt vertical and snug the lock nut against the landing gear strut. Do not tighten securely yet. Then align

37 8. Remove the wheel pant. 9. Use wrenches to permanently tighten the axle to the gear strut. 10. Install the inner wheel collar next to the ax

38 12. Slide the lock washer then the flat washer on the wheel pant mounting bolts. Use blue Loc-tite on the bolts before final tightening. 13. In

39 Engine Installation 1. The 50cc EXTRA 260 will accept a wide range of engine types. The DA-50 rear carburetor and the 3W-55 rear and side carb

4 INTRODUCTION Your new 50cc EXTRA 260 ARF-QB is a highly aerobatic airplane. It is capable of both pre-cision and 3-D maneuvers. The aircraft bui

40 5. Use a 1/4 drill to drill the engine mounting holes. 6. Align the template with the firewall and mark the location of the engine mounting h

41 Rear Carburetor Engine Installation If installing canister muffler or tuned pipe, skip to canister installation on page 43 1. The fo

42 5. Use blue Loctite to install the Pitts muffler bolts. Remember to always use the engine manufacturer suggested gasket for proper seal. 6. Sec

43 Pipe or Canister Muffler Installation 1. The 50cc EXTRA 260 can accept either a tuned pipe or canister muffler installation. Gather the pipe o

44 3. Bottom covering removed between the fuse formers and stringers shown. 4. Gather the plywood canister holding bracket and silicone tube insul

45 7. Inset the canister holding bracket against the rear side of the front former and apply CA glue to the top and bottom where it contacts the fus

46 11. Using thick CA, glue in place one half section of balsa sheeting to the front side of rear former. Note: It is recommended to test fit balsa

47 15. Dry fit the top balsa sheeting to front side of former and mark the location for the antenna guide tube. Drill a 1/8” hole for the antenna t

48 3. Canister and header inserted into the tunnel. 4. Install engine, refer to pages 39-40 for engine installation. Use blue Loctite on all engin

49 7. Securely tighten header pipe bolts to engine. 8. Bottom view of the DA-50 and final canister muffler installation. 9. Top view of the DA

5 KIT CONTENTS 50cc Extra 260 ARF-QB Materials List Basic Aircraft Parts Fuselage with pre-installed vertical fin – covered, Pre-installed and

50 2. Iron the bottom covering to ensure it is tight and well sealed to the wood. 3. Use a hobby knife to remove the covering from the inside ed

51 6. Gather the pipe holding bracket and silicone tube insulators as shown. Note: It may be necessary to cut the silicon tube into 4 s

52 10. Apply thick CA glue to the rear of the pipe holding bracket where it will contact the front of the fuselage former. Note: It is recommended

53 14. Use supplied Ultracote to recover the front bottom pipe opening. 15. Rear bottom pipe opening is left open for pipe stinger and air flow ex

54 3. Bottom view of the tuned pipe installation. 4. Assemble the tuned pipe to the header pipe with the Teflon coupler and clamps in accor-dance

55 7. Top view of DA-50 and final tuned pipe instal-lation. Note: Additional balsa sheeting can be applied to the underside of the radio floor

56 3. It is recommended to remove the top engine mounting hardware from the same side as your throttle arm. This will make attaching the ball link t

57 8. Mark the location of the servo mounting tray on the fuse side. 9. Ensure the throttle servo and servo tray are in the correct position

58 11. Prepare to epoxy the servo mounting tray to the fuse side. Remove the servo from the servo tray to protect against getting any glue onto the

59 15.. Thread the quick link half way onto the threaded coupler then install the quick link onto the throttle servo arm. Position the throt-tle ser

6 Horizontal Stabilizer with elevator assembly with (8) pin point hinges (glued)---covered, pre-drilled for control horns. Rudder with (5) pin poin

60 19. Attach the ball link to the throttle pushrod and secure to the carburetor throttle arm with a 4-40 bolt and nylon lock nut. Note: Use L

61 23. Front view of throttle pushrod installed. Servo Actuated or Manual Choke 1. You can install a choke servo if desired. Use the same mount

62 4. Position the pushrod to allow easy access through the front of the cowl air intake as shown. This is a easy, effective and light weight metho

63 Ignition Installation 1. Gather the ignition and installation parts as shown below. IGNITION INSTALLATION 2. Position the engine ignition on th

64 Fuel Tank Assembly 1. Gather the fuel tank parts as shown below. Fuel tank and hardware, fuel tubing, foam rubber and nylon ties. FUEL TANK

65 Fuel Tubing Installation 1. Attach the fuel line to the fuel pick up tube on the tank as shown. Note: It is highly recommended you solder a bra

66 5. Install the “ T “ fitting on the fuel line as shown. Use a heat gun to very slightly heat and soften the fuel tubing if necessary to insert t

67 9. Install the fuel filling dot as desired on the side of the fuse. Do not allow the fuel dot to interfere with the leading edge of the wing.

68 13. Place the fuel tank inside the fuse and run the fill line through the fuel dot installed on the fuse side as shown. Cut the line 2-3” outsi

69 Fuel Tank Installation 1. Install two long nylon ties under the fuel tank mounting floor as shown. 2. Place the foam rubber pad on the fuel ta

7 Hardware: ITEMS NEEDED TO COMPLETE • 50 CC Gas engine and ignition • Pitts style muffler or header with canister muffler or tuned pipe • Eng

70 5. Route the vent line on top of the fuel tank and secure with small nylon ties as shown. This will stop excess fuel from draining out the vent

71 1. Gather the following material for making a cowl cutout template. Use a large envelope or cardboard file folder for template material. COWL IN

72 5. Mark the fuse centerline on the bottom of the front former as shown. 6. Tape the template to the bottom of the fuse 3/8” back from the front

73 9. Use a hobby knife to cut out the tracing around both of the exhaust stacks as shown, Note: This hole is only for allowing the template to

74 13. Mark a centerline onto the bottom of the cowl as shown. 14. Align the paper template with the cowl as shown. Ensure the center lines are al

75 17. Use a hobby knife to cut out the cooling air exit in the paper template as shown. 18. Cylinder head and cooling air exit cutouts completed

76 21. Use a rotary tool drum sander to finish cut and round out the corners from the rough cut. 22. Final cuts should look similar to this in t

77 1. Gather the switches and mounting hardware to be used. We used two switches, one for re-ceiver battery, and one for ignition battery, and regu

78 5. Mount switches in accordance with the switch instructions and hardware. 6. Gather the radio mounting hardware as shown below. Foam rubber,

79 9. Ensure all radio plugs are secured with tape and will not come loose under light tension and vibration. 10. Typical installation of receiv

8 1. Open your kit slowly and take care not to dam-age any parts of the kit. Remove all parts from their plastic protective covers for inspection.

80 13. Secure the receiver to the radio tray with foam rubber base and nylon tie as shown. 14. Typical RC installation viewed from top. 15. Typic

81 1. Gather (2) 8-32 wing mounting bolts, (2) #8 rubber backed washers and (4) hairpins for preparation of mounting the wings. PRE-FLIGHT PREPARATI

82 6. Gather (6) 4-40 cowl mounting bolts and (6) #6 small rubber backed washers. Note: Shown below are only (4) mounting bolts and washers. Yo

83 9. Remove the canopy bulkhead hatch as shown. If desired an optional instrument panel and pilot may be installed. Note: Instrument panel and

84 Decal installation 1. Decals supplied with the kit may vary from the photos below. Gather supplied decals, transfer tape, ruler, scis-sors,

85 4. Factory placement of decals shown. 5. Cut transfer tape to accommodate decal size. Note: Transfer tape will be reused. DO NOT throw away

86 8. Press transfer tape to top of decal. 9. Peel backing from decal. 10. Spray model surface with application fluid, Windex or soapy

87 12. Position decal in proper location. Application fluid will allow decal to be moved slightly. 13. Using a plastic squeegee or credit card. Spre

88 16. Repeat installation process of bottom decal for top decal installation. Use application fluid for easier installation 17. Place top decal ove

89 Center of Gravity 3” Back from wing L.E. at wing tip 1. Warning, do not skip this step! The recommended CG is 3” back from the wing l

9 1. Go over all seams and color overlaps with your sealing iron. Note: Even if your models covering has no wrinkles out of the box it is still ve

90 3. Use the widest part of the elevator as shown to measure the elevator throw in inches. 4. Rudder throw measured in inches. Hint: Taping a p

91 Control Throw Deflection Table Low Rate High Rate Aileron 2 1/2” or 25˚ up 3” or 30˚ up 2 1/2” or 25˚ down 3” or 30˚ down Rudder 2 1/2”

92 Aerobatics The 50cc EXTRA 260 ARF-QB is capable of any aerobatic maneuver. After you gain some confi-dence and little experience flying the air

93 50 cc EXTRA 260 ARF-QB NOTES ___________________________________________________________________________ ___________________________________