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AeroWorks 35cc EXTRA 300 ARF-QB Assembly Manual

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35cc EXTRA 300 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS
401 Laredo Unit "D", Aurora, CO. 80011 - Phone 303-366-4205 - Fax 303-366-4203
E-mail - info@aero-works.net
1

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Summary of Contents for AeroWorks 35cc EXTRA 300 ARF-QB

  • Page 1 35cc EXTRA 300 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS 401 Laredo Unit “D”, Aurora, CO. 80011 - Phone 303-366-4205 - Fax 303-366-4203 E-mail - info@aero-works.net...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Aeroworks Contact Information ………………………………………………………………. 3 Introduction ……………………………………………………………………………………... 4 Kit Contents……………………………………………………………………………………… 5 Items Needed To Complete ……………………………………………………………………... 7 Tightening and Re-shrinking The Covering ………………………………………………….. 8 Check Seams and Overlaps for Good Seal ……………………………………………………. 9 Wing Assembly………………………………………………………………….……………….. 10 Stab and Elevator Assembly…………………………………………………………………….

  • Page 3: Aeroworks Contact Information

    Further, Aeroworks reserves the right to change or modify this warranty without notice. In that Aeroworks has no control over the final assembly or materials used for final as- sembly, No liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product.

  • Page 4: Introduction

    INTRODUCTION Your new 35cc EXTRA 300 ARF-QB is a highly aerobatic airplane. It is capable of both pre- cision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state of the art CAD design, LASER cut technology, and high quality included hardware. We hope you enjoy building and flying your 35cc EXTRA 300 ARF-QB.

  • Page 5: Kit Contents

    KIT CONTENTS (4) #6 bonded washers for the mounting of the 35cc Extra 300 ARF-QB Canopy Materials List (2) pull-pull exit tubes for rudder cable installed (1) Antenna Tube installed Basic Aircraft Parts (1) Engine box hatch cover, installed Fuselage with pre-installed vertical fin – covered, Left Wing with Aileron –...
  • Page 6 Horizontal Stabilizer with elevator assembly with (8) pin point hinges (glued)---covered, pre-drilled for control (2) 4-40 3” two end threaded pushrod with nuts for horns. ailerons (2) 4-40 4” two end threaded pushrod with nuts for Rudder with (5) pin point hinges (not glued) – covered, elevators.

  • Page 7: Items Needed To Complete

    ITEMS NEEDED TO COMPLETE Hardware • Allen wrenches US and Metric. • Dremel cutting disc and sanding drum tool • Electric drill and selection of bits • Razor saw • Flat head screwdriver • Hobby heat gun • Hobby iron and covering sock •...

  • Page 8: Tightening And Re-Shrinking The Covering

    TIGHTENING AND RE-SHRINKING THE COVERING 1. Open your kit slowly and take care not to dam- 3. If bubbles persist, use a small pin to punch holes age any parts of the kit. Remove all parts from in the bubble to relieve trapped air and reheat. their plastic protective covers for inspection.

  • Page 9: Check Seams And Overlaps For Good Seal

    IMPORTANT: It is the users responsibility to check the covering seams and overlaps for security and a good seal. Aeroworks is not responsible for failure of covering seams or overlaps during flight. This is a never ending process that must be done after each flying secession.

  • Page 10: Wing Assembly

    Safety Clips Available from Aeroworks 4. Fasten the pull string from the servo hole to the 2. Layout the servo on the wing to test fit the in- male plug of the servo extension. stallation and ensure servo lead is the correct length.
  • Page 11 5. Draw the 6” servo extension through the wing 7. Install servo with servo mounting screws. and pull through the wing root rib. 6. Install servo in servo well with the output arm Pushrod / Control Horn Installation toward the leading edge of the wing. Mark and drill location of servo mounting holes.
  • Page 12 2. Assemble the pushrod and control horn assem- 4. Place the control horns over the predrilled bly as shown. The ball link goes between the mounting holes. left and right sides of the control horn sides and is secured with a nylon lock nut. Start with the center hole in the control horn.
  • Page 13 6. Securely fasten the control horn to the aileron 8. Ensure the servo does not bind at either end with six wood screws as shown. point at full deflection. A 1” servo arm is rec- ommended for best results. A 1 1/4” servo arm is required for full deflection of the aileron 55º...

  • Page 14: Stab And Elevator Assembly

    Note: 180 in. oz. digital, metal geared servos are recommended. Servo selection can be the differ- ence between a great flying model and a model that will crash. Always use brand name high quality servos. Safety Clips Available from Aeroworks...
  • Page 15 5. Install servo with servo mounting screws. 2. Assemble the pushrod and control horn assem- bly as shown. The ball link goes between the left and right sides of the control horn sides and is secured with a nylon lock nut. Start with the center hole in the control horn.
  • Page 16 4. Place the control horns over the predrilled 6. Mount the control horn using six wood screws. mounting holes. 5. Use a drop of thick CA glue on each screw to prevent screws from loosening due to vibration 7. Correct installation of elevator servo linkage to as shown.
  • Page 17 8. Tape leading edge of the elevator balance tab to 11. Finished elevator servo installation shown be- the leading edge of the stab in the neutral posi- low. tion. Plug the elevator servo into the receiver and turn radio on. Ensure the servo trim is cen- tered.

  • Page 18: Rudder And Pull-Pull Cable Assembly

    RUDDER AND PULL – PULL CABLE ASSEMBLY 3. Mix epoxy in mixing cup and use a tapered stick Rudder Installation to apply the epoxy inside the pre-drilled holes in the trailing edge of the fin. Apply epoxy to one 1. Gather the rudder, five hinges, rubbing alcohol, side of each hinge and insert the hinge com- petroleum jelly and epoxy materials as shown.

  • Page 19: Servo Installation

    5. Mix epoxy in mixing cup and use a tapered stick 7. Ensure there is no gap between fin and rudder. to apply the epoxy inside the pre-drilled holes in Allow epoxy to fully cure. the leading edge of the rudder. Apply epoxy to trailing edge of each hinge.
  • Page 20 2. Gather the rudder control horn parts as shown 4. Place the control horns over the predrilled below. 2 ball link assemblies, 2 left and 2 right mounting holes. side control horns. Assemble the ball links be- tween the control horns as shown. Secure with nylon lock nut.
  • Page 21 6. Mount rudder control horns using six wood 9. Install the rudder servo in the servo cutout with screws. the output shaft to the front. 7. Repeat the above steps for mounting the other side rudder control horn. 8. Gather one rudder servo with 3” double output 10.
  • Page 22 11. Install rudder servo with servo screws. 13. Pull the rudder cables from rear of fuse to the rudder servo tray. 12. Feed one rudder cable through the pre installed 14. Using an x-acto knife clean away any burrs from cable exit tube in the rear of the fuse toward the brass swags.
  • Page 23 15. Thread cable through brass swage tube. 17. Loop the cable back through the brass swage tube and pull tight. 16. Thread cable through the threaded coupler hole, 18. Crimp the brass swage tube with a crimping tool and back through the brass swage tube as shown. or pliers.
  • Page 24 19. Cut off excess cable as shown 21. Attach ball links to the rudder servo arm and then attach the servo arm to the rudder servo as shown. Note: Use flat washers to prevent link from coming loose from the brass ball 20.
  • Page 25 23. Tape the rudder balance tab to the top leading 25. Thread the rudder cable through a brass swage edge of the vertical fin in the neutral position as tube, then the threaded coupler, and back shown. This ensures the rudder is straight when through the brass swage tube on both sides.

  • Page 26: Tail Wheel Installation

    27. Crimp the brass tube with a crimping tool or pli- 29. A drop of thin CA may be applied to the swage ers. tube to help secure the cable. 28. Cut off access cable as shown. Tail Wheel Installation 1.
  • Page 27 2. Align rudder tiller steering arm with pre drilled 4. Mount the tail wheel steering tiller using two mounting holes at bottom of rudder. wood screws. 3. Apply a drop of thick CA to the tiller arm 5. Align the tail wheel with pre drilled mounting mounting screws before inserting in the pre- holes on the bottom of the fuse drilled holes.
  • Page 28 6. Place a drop of thick CA on tail wheel strut 8. Attach the steering spring to the rudder tiller. mounting screws before inserting in the pre- Center the spring between both tail wheel and drilled mounting holes on the bottom rear of the steering tillers.
  • Page 29 10. With spring centered between tiller arms and tail 12. Tail wheel final assembly is complete. wheel centered, bend spring wire through tail wheel steering tiller. Twist spring end tight with pliers. 11. Repeat spring installation for other side.

  • Page 30: Main Landing Gear, Gear Cuffs, And Wheel Pants Assembly

    MAIN LANDING GEAR - GEAR CUFF AND WHEEL PANT ASSEMBLY 3. After screws are removed, remove the landing Main Landing Gear Installation gear cover. 1. Gather the landing gear parts as shown below. Landing gear strut, 4 8-32 mounting bolts, 4 flat washers, 4 lock washers, 2 gear cuffs, 4 4-40 mounting bolts, 4 flat washers, 2 wheels, 2 axles, and 4 wheel collars as shown below.
  • Page 31 5. Slide lock washer then flat washer onto mount- 7. Reinstall the main gear cover. ing bolt. Use a drop of blue Loctite on landing gear bolts before attaching the landing gear. 6. Bolt landing gear strut to fuse with 4 x 8-32 8.
  • Page 32 9. Slide the lock washer then the flat washer on the 11. Install left and right gear cuffs as shown. cuff mounting bolt. Use a drop of blue Loctite on each bolt before installing the bolt. 10. Secure gear cuff to main gear as shown. 12.
  • Page 33 13. Align the flat sides of the axle bolt vertical and 15. Install the inner wheel collar on the axle. Use a snug the lock nut against the landing gear strut. drop of blue Loctite on the wheel collar set screw and tighten the wheel collar in place.
  • Page 34 17. Slide the lock washer then the flat washer on the 19. Repeat above steps for other wheel and wheel wheel pant mounting bolts. Use blue Loctite on pant. the bolts before final tightening. 18. Final installation of wheel pant with two mount- ing bolts.

  • Page 35: Engine And Throttle Servo Installation

    ENGINE AND THROTTLE SERVO INSTALLATION 3. To modify the universal mounting template to Engine Installation accommodate your engine of choice. Line up the 1. The 35cc Extra 300 will accept a wide range of template with the engine thrust lines. gasoline and glow engines.
  • Page 36 5. Use a 1/4” bit to drill the engine mounting holes. 7. Line up the template with the engine thrust lines and mark location of mounting holes on tem- plate. 6. If you have selected to use a glow engine. 8.
  • Page 37 Align mounting template with firewall and tape 11. Remove mounting template from firewall. Fire- in place. wall shown with mounting holes drilled ready for engine mounting Note: Use following steps for all types of engine installations. 10. Use a 1/4 bit to drill the engine mounting holes 12.
  • Page 38 13. Temporally mount engine mounting rails to fire- 15. Double check measurement. The required dis- wall. Engine mounts will be removed to allow tance from the front of the firewall to the front for easy drilling of the engine mounting bolts 6”.
  • Page 39 17. If a centering tool is not available use a small 19. Mark engine mounts and fuse for quick refer- drop of fingernail polish to mark hole locations. ence for mount installation after drilling mounts. 18. Hole locations shown marked ready for drilling 20.
  • Page 40 22. Using a drill press to drill hole locations is rec- 24. If your engine of choice does not use a rail type ommended engine mount. Use 1/4” aluminum spacers and mounting bolts to mount engine to firewall. Note: Aluminum spacer available from Aeroworks...
  • Page 41 3. Install the RC threaded quick link onto the push- Solid Rod - Throttle Servo Installation rod as shown. Gas Application 1. Gather the supplied throttle servo linkage hard- ware as shown. 1 x 4-40 metal rod thread at one end 1 x 4-40 ball link assembly 1 x 4-40 threaded solder coupler 1 x 4-40 threaded quick link...
  • Page 42 5. Dry fit throttle servo inside the motor box En- 7. Using the small drill holes just drilled draw loca- sure the throttle pushrod will line up with the tion of servo cut out onto bottom of engine box. servo output arm with no binding. Mark the lo- cation of the servo onto the inside of the motor box as shown.
  • Page 43 9. Install the throttle servo into the servo cut out 11. Position the throttle servo arm at center travel using servo mounting screws. and the carburetor arm at center travel. With the ball link attached to the throttle servo arm mark the location to cut the throttle pushrod to correct length.
  • Page 44 13. Cut throttle pushrod to correct length. 15. Using sand paper scuff end of pushrod at loca- tion of solder joint. This will give you a stronger solder joint 14. Gather Soldering Iron, and your choice of sol- 16. Place the threaded coupler over the pushrod. der.
  • Page 45 17. Remove threaded quick link from throttle link- 19. Attach quick link to throttle arm. Ensure the age. From inside of box feed throttle linkage throttle pushrod operates smoothly and does not through firewall. With servo arm in the center of bind or rub against the hole in the firewall.
  • Page 46 21. Apply a small drop of thick CA glue onto servo 2. Position throttle servo in either the right or left mounting screws to prevent screws from backing pre cut servo cut out in fuselage floor. Use servo out from engine vibration. cut out directly behind carburetor throttle arm of engine.
  • Page 47 4. Attach quick link to carburetor throttle arm. 6. Flex pushrod installed shown below. 5. Glue wooden support brackets to fuse to elimi- 7. Glue wooden support brackets to fuse to elimi- nate any flex in pushrod. nate any flex in pushrod.

  • Page 48: Ignition Installation

    IGNITION INSTALLATION 3. Use a 1/8” bit to drill the ignition module Ignition Module Installation mounting holes. 1. Gather the ignition module and installation parts as shown below. 2. Position the ignition module on the side of the 4. Thread nylon tie through mounting holes. engine mounting box and mark the location of the nylon tie holes as shown.
  • Page 49 5. Roll the supplied foam rubber to make a 4 layer Ignition Battery / Switch Installation pad as shown. Make the pad slightly larger than the ignition module. 1. Gather ignition switch and battery. 2. Switch location is at the discretion of the 6.
  • Page 50 4. Mount switch in accordance with the switch 6. Secure all wiring with safety wire, string, tape, manufacturers instructions and hardware. or other method. Ensure the connectors will not come apart from vibration or light tension. Safety Clips Available from Aeroworks...
  • Page 51 Safety Clips Available from Aeroworks 8. Secure all ignition wires with small zip ties to help prevent wires from chafing or coming in contact with engine and becoming damaged.

  • Page 52: Fuel Tank Assembly And Installation

    FUEL TANK ASSEMBLY AND INSTALLATION 3. Assemble the fuel pick up line, rubber stopper Fuel Tank Assembly (Gasoline) and metal end caps. As shown below. 1. Gather the fuel tank parts as shown below. Fuel tank, hardware, brass barbs and fuel tubing. Note: Rubber stopper supplied for both Gas and Glow fuels.
  • Page 53 5. Final assembly of rubber fuel stopper with fuel 7. Install the fuel tubing and clunk. Secure the fuel pick up tube shown below. tubing with nylon ties to the pick-up tube and clunk. 6. Install air vent tube into rubber stopper and bend 8.
  • Page 54 “T”, fuel filter in the fuel line to the carburetor. filler dot, fuel filter and nylon ties. Note: The fuel “T”, fuel filter and filler dot are not supplied, but are available through Aeroworks.
  • Page 55 4. Use small nylon ties to secure fuel line. 6. Mark the location of the fuel filler dot. Note: Gasoline will cause the fuel line to expand over time. Always secure fuel lines with nylon ties to prevent them from pulling off during flight.
  • Page 56 8. Install fuel dot as shown below. 10. Thread nylon ties under tank mounting plate and center in position. 9. Fuel filler dot installed in fuselage side shown 11. Install foam rubber pad for fuel tank to rest on. below. Foam rubber will help prevent fuel from foam- ing or getting air bubbles from engine vibration.
  • Page 57 12. Cinch the nylon ties securely to hold the tank 14. Install filler dot plug into fuel filler line. against the foam on the fuel tank floor. Cut off access nylon tie. 13. Feed fuel filler line through filler dot. 15.
  • Page 58 16. Pass fuel line through firewall and connect to the 18. Route the vent line on top of the fuel tank and engine carburetor. Secure with small nylon tie. secure with small nylon ties as shown. This will stop excess fuel from draining out the vent line during an extended down line or when lifting the tail.

  • Page 59: Radio Installation

    RADIO INSTALLATION 1. Gather the radio components as shown below. 3. Use a hobby knife to cut out the switch opening. Battery, switch, receiver foam rubber and nylon ties. 2. Mark the location for the radio switch using the 4. Mount switch in accordance with the switch switch mounting plate for a template.
  • Page 60 5. Install nylon tie wraps into the fuse floor as 7. Secure the receiver battery to the fuse floor us- shown for securing the receiver battery. ing the nylon tie wraps. 6. Use a piece of supplied foam rubber to form a 8.
  • Page 61 9. Apply baby powder or corn starch to receiver 11. Tape the receiver antenna wire to the end of the antenna wire to assist getting it into the pre in- antenna guide tube and radio floor as shown. stalled antenna guide tube. This will prevent the antenna wire from vibrat- ing back out.

  • Page 62: Muffler Installation

    MUFFLER INSTALLATION COWL INSTALLATION 1. Use blue Loctite to install the Pitts muffler bolts. 1. Gather the materials as shown below. Template Remember to always use the engine manufac- material, hobby knife, ruler, tape, marker and turer suggested gasket for proper seal. pencil.
  • Page 63 3. Measure and mark the center of the template 5. Tape template to bottom of fuselage. Ensure material as shown. there is a 3/16” overlap behind the front former. 6. Hold the template up to the exhaust stacks and 4. Center the template on the bottom of the fuse trace around the location of both of the exhaust and align with the 3/16”...
  • Page 64 7. Mark the template directly in line with the fuse- 9. Draw the hot air exit hole onto template. lage air exit slot as shown. 8. Pull template up to the engine cylinder head. 10. Use a hobby knife to cut out the hot air exit Trace around the engine cylinder so that it can opening as shown.
  • Page 65 11. Dry fit template to fuselage to ensure the cutouts 13. Aligning center marks of template and cowl. will clear the exhaust stacks and cylinder head. Tape template to the bottom of cowl. Use a felt tip marker to transfer the template cutout pattern to the cowl and mark cut location.
  • Page 66 15. Use a rotary tool disc cutting wheel to rough cut 17. Another view of finished cowl installed on fuse. the hole in the bottom of the cowl. Use a rotary tool drum sander to finish cut and round out the corners from the rough cut.
  • Page 67 19. Cut out cowl for easy engine needle adjustments. 21. Install the cowl and secure with all cowl mount- ing bolts. Use a felt tip pen to trace the location of the access hole onto the side of the cowl. 20.

  • Page 68: Preflight Preparation

    PRE-FLIGHT PREPARATION 1. Gather (4) 6-32 wing mounting bolts, (4) #6 rub- 3. Install hairpins into both front and rear ber backed washers and (4) hairpins for prepara- aluminum anti-rotation wing dowels for a tion of mounting the wings. second method of wing attachment. 2.
  • Page 69 5. Slide the stab tubes in the fuse stab tube sleeves. 7. Mount the cowl using the cowl mounting bolts (Long Back / Short Front) Slide the stabs on the and rubber backed washers. The rubber backed stab tubes and connect pushrod to servo arm. washers are to prevent the fiberglass cowl from Slide the rubber backed washers on the stab cracking and to prevent mounting bolts from...
  • Page 70 Note: Instrument panel and pilot are not supplied in vibration area and can loosen the front dowels. the kit but may be purchased separately from Always check the front dowels are secure before Aeroworks. each flying session Us thin CA to secure front...

  • Page 71: Decal Installation

    DECAL INSTALLATION 3. Factory placement of decals shown. Decal installation 1. Decals supplied with the kit may vary from the photos below. Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squeegee or credit card, Windex or Application fluid like Rapid Tac.
  • Page 72 4. Using rubbing alcohol or glass cleaner. Clean all 6. Remove backing from decal sheet. areas before any decal installation. 5. Tighten all covering prior to any decal installation. 7. Spray model surface with application fluid, Windex or soapy water solution.
  • Page 73 8. Spray back side of decal with application fluid, 10. Using a plastic squeegee or credit card. Spread Windex or soapy water solution. decal smooth and remove all excess application fluid. Let decal set until dry enough to be able to remove transfer tape with out removing decal.
  • Page 74 12. Finished decal installation. Work slowly and carefully and you will be rewarded with a beautifully finished model.

  • Page 75: Center Of Gravity (C.g.) / Control Throws

    The control throws are shown in degrees and inches of de- 2. Balance the 35cc EXTRA 300 ARF-QB without flection measured at the widest point of the con- fuel in the tank with the batteries installed and trol surface for both low and high rates.
  • Page 76 3. Use the widest part of the elevator as shown to 5. Slide the throw meter under the rudder boost tab. measure the elevator throw in inches. 4. Gather the Rudder Throw Meter ( Supplied) and 6. Center the throw meter on the rudder using the scotch tape.
  • Page 77 7. Secure the tabs to the fin using scotch tape. Use a flight control deflection meter (Available through Aeroworks) to measure the throws in . Prop up the tail of the aircraft until degrees the fuselage is parallel to the table top.

  • Page 78: Control Throw Deflection Table

    Control Throw Deflection Table Preflight Checks Low Rate High Rate Center of Gravity: Check CG is set properly. Aileron 1 1/2” or 20˚ up 2” or 25˚ up 1 1/2” or 20˚ down 2” or 25˚ down Engine: The engine should run smoothly at all throttle settings with smooth transition from idle to full throttle without stalling or hesita- Rudder...
  • Page 79 Aerobatics The 35cc EXTRA 300 ARF-QB is capable of any aerobatic maneuver. After you gain some confi- dence and little experience flying the airplane you can cut loose and perform any maneuver you can think of. Here is a list of some of the more popular aerobatic and 3D maneuvers you can try: •...
  • Page 80 35 cc EXTRA 300 ARF-QB NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ __________________________________________________________________________...

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