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AJ Aircraft Laser 230z Assembly Instructions Manual

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93" AJ Laser 230z
Assembly Instructions

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  • Page 1 93” AJ Laser 230z Assembly Instructions...
  • Page 2 Congratulations AJ Aircraft thanks you for the purchase of this airplane. Top grade materials and precision assembly has gone into this to make this a top quality aircraft. Following the directions closely, will assure you many hours of thrilling flight. 2 years of design, development and testing has gone into this airframe. We hope you’re as...

  • Page 3: Recommended Items

    Recommended Items For Completion  2x 48" extensions for the elevators Components  1x 12" extension for the ESC to Receiver (if  5x 300-oz minimum High Torque Metal Geared electric) servos (400-oz minimum highly recommended for  2x 12" extension will be needed for the ailerons due to their size) throttle servo and ignition (if gas) (Futaba S-9157 are recommended)

  • Page 4: Tips For Success

    You may notice that some pictures in this manual may be of a different size Laser. In this case, the differ- ences did not make a difference in explaining that part of the build.  If there’s ever a question, post on an RC forum or contact AJ Aircraft to verify before doing anything.

  • Page 5: Main Landing Gear

    Section 1 — Landing Gear Tail Gear 1) Remove tail gear from its package. 2) Remove the 3 pre-installed bolts in the tail and mount the tail gear with provided bolts and washers. Main Landing Gear 4) Open the landing gear bag and sort the bolts, axles and other parts. 5) Place the landing gear onto the fuse with the THINNER ANGLED edge reward (the gear is shaped like an airfoil).
  • Page 6 6) Place the wood filler block over the landing gear. Pay attention to the fit as it is directional. While the cuffs will hold this in place, we suggest using a piece of clear tape, or white Ultracote for extra security. 7) Install the landing gear cuffs using the 4 phillips head bolts and washers provided.
  • Page 7 8) Install the landing gear axles through the hole on each side in the landing gear with the provided nylon lock nuts. Place a wheel collar onto the axle all the way to the base and secure the grub screw. 9) Slide the wheel onto the axle and secure with cotter pin.
  • Page 9 Section 2 — Elevator/Rudder 11) Remove the horizontal stabs, elevators, control horns and ball link hardware. 12) Use a sharp blade to cut the 2 slots on each elevator half. Check to make sure you are cutting the BOTTOM of the elevator. The cut doesn’t have to be perfect, as we will be removing covering around this coming up.
  • Page 10 14) Test fit the control horns into their slots in each elevator half to make sure they will fully seat down. Sand the corners or bottom edge if necessary. Trace around the base plate with a fine Sharpie.
  • Page 11 15) Remove the assembly and use a sharp blade to cut approx. 1/16” in from your line and remove the cover- ing. Use caution to only cut deep enough to remove the covering and not cut into the balsa! Remove your lines with a paper towel soaked with denatured alcohol.
  • Page 12 17) Seal the hinge gaps with strips of Ultracote or Blenderm tape. Make sure the surface is fully deflected when applying the seal strip. Sealing the gap will ensure the airflow continues over the elevator instead of going through the hinge gap. 18) Use a sharp blade to remove the covering from the slot on the bottom of each elevator half for the servo horns.
  • Page 13 Tip: Drill pilot holes for the screws and then install the screws. Remove the screws and apply a few drops of thin CA in and around the screw holes and let dry. This will harden the threads and provide a more secure mount. 20) Locate the threaded turnbuckle pushrods, 2 ball links, 2 bolts, washers and nylon lock nuts.
  • Page 14 23) Slide in the small carbon fiber tube into the tail and connect the servos to their extensions. Always use a servo keeper on these! Slide each elevator half onto the tube, tucking the extra servo wire into the fuse. 24) Secure the stabs with the provided bolts and washers.
  • Page 15 Section 3 — Fuselage 25) Begin by inspecting the airframe and applying thin CA to any joints that may have loosened during shipping & handling. Also take time now to run your covering iron over all seams and decals, if you haven't already. Once completed, you can open the holes needed on each side for the front &...
  • Page 16 29) You can now re-mount your engine, mufflers and ignition box. The ignition box can be placed anywhere, but typically goes on the top or side of the motor box. In our example, it’s been mounted to the firebox access hatch on the top of the motor box. Don’t forget to locktite everything! 30) There’s a pre-cut hole in the bottom of the firebox for the throttle servo, which should work perfectly for the majority of gas engines.
  • Page 17 31) Assemble and install the gas tank provided and mount it in front of the wing tube. We suggest placing the provided piece of foam under the tank to prevent foaming from vibration. Secure the tank using the provided Velcro straps running through the slots on the plywood tray.
  • Page 18 Electric Motor Install 34) If using the recommended Hacker Q-80, you’ll need 3” standoffs to bring the motor forward into the cowl. If using another motor, you’ll need standoffs that bring your spinner backplate 6 5/8” from the firewall to clear the cowl. Mount your standoffs to the firewall.
  • Page 19 36) Mount your ESC to either side of the motor box with the provided Velcro through the slots on either side of the motor box. 37) Cut a hole in the main former for the power wires of the ESC to get through into the fuselage. 38) Connect your motor and ESC via bullet connectors or directly soldering the wires together.
  • Page 20 42) You now have the option to use either pull-pull wires or push-pull on the rudder. Rudder pull-pull wires have been pre-strung through the fuselage for you. In our experience if using the DA-70 on this airframe, the push-pull setup with the rudder in the tail worked best for obtaining correct CG.
  • Page 21 Pull-Pull Rudder Setup 48. Install the rudder servo into the tray in the fuselage using the manufacturers’ hardware. Then attach a 3 1/2” double arm to the servo. 49. Secure the ball link hardware to each side of the servo arm. 50.
  • Page 22 52. Thread another pull-pull fitting into a ball-link and temporarily bolt it to the rudder control horn. 53. Slide an aluminum crimp tube onto the other end of the wire and thread it into the keeper and back around exactly as you did for the servo end.
  • Page 23 Fuselage assembly continues… 58) Slide the large carbon fiber wing tube into the fuse and then each wing half onto the tube, pulling the aileron servo wire ends through the hole in the fuselage. Secure the wing halves with the provided nylon thumb screws. 59) Install your switches, batteries and receiver inside the fuselage.
  • Page 24 Section 3 — Wings 61) Assemble the control horns and ball-link the same as you did the elevators. Cut the slots in the bottom of each ailerons, test fit the control horns, mark around the baseplate and cut away the covering. Glue in the horns exactly as you’ve done previously. 62) Utilizing a fresh blade, carefully cut and remove the covering exposing the servo mount located on the underside of each wing panel.
  • Page 25 64) Install servo into the wing with the output shaft forward utilizing the hardware that came with the servos. Then install a 1 3/4” servo arm so it is roughly perpendicular to the servo case. 65) Locate the 2 short threaded pushrods, ball links, bolts, washers and nylon lock nuts. Attach the servo arm to the aileron the same as you did on the elevator.

  • Page 26: Control Throws

    Section 5 Radio Installation & Setup Your receiver can be mounted anywhere in the airframe. If not doing pull-pull rudder, the rear end of the ply tray or right behind the wing tube is an excellent location. While the final setup is of personal preference, these are some general guidelines to make your first flight a success. Control Throws: Low Rates: A.
  • Page 27 Enjoy your new plane! We at AJ Aircraft sincerely hope you enjoy flying the 93 AJ Laser 230z. If you have any problems, questions or suggestions, always feel free to create a support ticket at aj-aircraft.com. Once you get a few flights in, we would greatly appreciate your review sub-...

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