AeroWorks Extra 300 ARF-QB Assembly Manual
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AeroWorks Extra 300 ARF-QB Assembly Manual

Extra 300 arf-qb
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100cc Extra 300 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS
4903 Nome St– Denver, CO. 80239
www.aero-works.net
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Summary of Contents for AeroWorks Extra 300 ARF-QB

  • Page 1 100cc Extra 300 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS 4903 Nome St– Denver, CO. 80239 www.aero-works.net...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Aeroworks Contact Information …………………………………………………………………………. 3 Introduction / Warranty…………………………………………………………………………. ………. 4 Kit Contents………………………………………………………………………………………………… 5 Items Needed To Complete ……………………………………………………………………………….. 8 Tightening and Re-shrinking The Covering ……………………………………………………………… 9 Checking Seams and Color Overlaps for Good Seal / Sealing Hinge Gaps ………..………………….. 10 Wing Assembly………………………………………………………………….………………………….

  • Page 3: Aeroworks Contact Information

    Further, Aeroworks reserves the right to change or modify this limited 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 / Warranty

    CAD design, laser cut technology and jig-built assures accuracy in all stages of production. The 100cc Extra 300 ARF-QB is designed for gas engines in the 100cc category. The DA- 100cc engine is shown in the assembly instructions. The aircraft was tested with the DA- 100cc and has outstanding performance.

  • Page 5: Kit Contents

    KIT CONTENTS (4) #6 bonded washers for the mounting of the can- 100cc Extra 300 ARF-QB (4) 3mm split lock washers for the mounting of the Basic Aircraft Parts: canopy Fuselage with pre-installed vertical fin , firewall fuel- (1) 3.5(o.d.) x1250mm Antenna tube installed proofed, tail wheel assembly holes pre-drilled (2) 3.5(o.d.) x120mm pull-pull exit tube installed...
  • Page 6 (4) 4-40x16mm Hex style head bolts for stab mounting Horizontal Stabilizer with elevator assembly with (12) (4) #6 bonded washer for stab mounting pin point hinges (glued)---covered (4) 3mm split ring lock washer for stab mounting Elevators Pre-drilled for the mounting of the (4) 1.8mm cotter pins-wing retainer control horns Rudder with (7) pin point hinges (not glued) –...
  • Page 7 (1) Customer Throw Meter (1) Paper Degree Meter for Rudder #13: (1) Custom – Vinyl Decal Set -Decal set supplied with kit may very from pic- tures. Optional decal set available from Aeroworks. #14: (1) Assembly Manual with picture folders on CD...

  • Page 8: 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 • Flat head screwdriver • Hobby heat gun • Hobby iron with protective sock •...

  • Page 9: 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 10: Checking Seams And Color Overlaps For Good Seal Sealing Hinge Gaps

    It is the responsibility of the purchaser / operator 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. Note: If covering continues to lift apply a small amount of thin CA underneath the covering.

  • Page 11: Wing Assembly

    3. Attach the 24” extension to the outboard servo Covering is supplied for sealing the hinge gaps if lead and secure with an Aeroworks safety clip. desired. However, due to the precisely aligned Ensure the connectors will not come apart from and minimal hinge gap this step is optional.
  • Page 12 Attach the Y harness to the inboard servo 4. Remove the balsa stick with the pull string from lead and secure with an Aeroworks safety the servo well and tie the pull string to the servo clip. Ensure the connectors will not come lead as shown.
  • Page 13 Pull Y harness through root end of wing. Secure all Y harness connections with safety wire, string, tape, or other method. Ensure the connectors will not come apart from vibration or light tension. Secure excess wire from Y harness and extensions inside the wing root rib using tape or Velcro as desired.
  • Page 14 Aileron Control Linkage Installation 1. Gather the aileron control linkage parts as shown below. There are (2) 4-40 pushrods, (4) 4-40 ball Install servo with servo mounting screws. link assemblies, (2) Flat washers (2) brass spacers, (2) left and (2) right side control horns, (1) Adjust- ment wrench (4) carbon reinforcement sleeves and (12) wood screws for each wing panel.
  • Page 15 3. Correct installation of ball link, flat washer and 5. Use thick CA on each screw prior to brass spacer to servo arm shown below. installing to lock screws in place Note: CA glues have a fast drying time. Remember to work quickly Note: Flat washer prevents ball link from coming off brass ball.
  • Page 16 Install servo arm to pushrod as shown below. Plug the servos into the receiver and turn on. Ensure servos are centered and the servo arms are parallel to the aileron hinge line. Adjust the length of the pushrods so that the aileron is at the neutral position when the servo arms are parallel to the aileron hinge line.

  • Page 17: Stab And Elevator Assembly

    STAB AND ELEVATOR ASSEMBLY 4. Install servo with servo mounting screws. 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 for hinging. Clear covering has been provided for sealing of the hinge gaps if desired.
  • Page 18 2. Assemble the pushrod and control horn assem- 4. Align the control horns over the factory drilled bly as shown. The ball link goes between the holes. left and right sides of the control horn sides and is secured with a nylon lock nut. Note: Control horns have been set at a slight offset to allow for maximum torque at full deflection...
  • Page 19 7. Plug the 48” Extension into the female end of the servo. Secure the servo connectors with an Aeroworks Safety Clip Ensure the connectors will not come apart from vibration or light ten- sion.

  • Page 20: Rudder And Rudder Servos Installation

    RUDDER AND RUDDER SERVOS INSTALLATION Mix epoxy in mixing cup and use a tapered Rudder Installation stick to apply the epoxy inside the pre-drilled holes in the trailing edge of the fin. Apply Gather the rudder, hinges, epoxy, Vaseline, epoxy to one side of each hinge and insert the stir sticks, mixing cup and alcohol as shown.
  • Page 21 Mix epoxy in mixing cup and use a tapered Ensure there is minimal to no gap between fin stick to apply the epoxy inside the pre-drilled and rudder. Allow epoxy to fully cure. holes in the leading edge of the rudder. Apply epoxy onto each hinge.
  • Page 22 2. Assemble the ball links between the control 4. Use thick CA on each screw prior to installing to horns as shown. Secure with nylon lock nut. lock screws in place Note: Mount ball link to bottom control horn hole Note: CA glues have a fast drying time.
  • Page 23 8. Attach the Y harness to forward rudder servo (2) 3” to 3 1/2” Double out put servo arms, (2) lead and secure with an Aeroworks Safety Clip. Servo coupler assemblies supplied, (2) AW Ensure the connectors will not come apart from Safety Clips, all mounting hardware, and a 11”...
  • Page 24 11. Install rudder servos with servo mounting 13. Tie off or tape rudder cables to keep them from screws. pulling into fuse. 12. Feed the rudder cable through the pre installed 14. Pull the rudder cables from the fuse tail to the cable exit tube in the tail of the fuse toward the rudder servo tray.
  • Page 25 15. Install the ball link onto the threaded coupler as 17. Thread cable back through the brass swage tube shown below. as shown. 16. Thread the brass swag tube onto the pull pull 18. Loop the cable back through the brass swage cable followed by the threaded coupler.
  • Page 26 19. Crimp the brass tube with a crimping tool or pli- 21. A drop of thin CA may be applied to the swage ers. tube to help secure the cable. Rudder Servo Coupler Installation 20. Cut off excess cable as shown. 1.
  • Page 27 2. Install the rudder servo couplers onto the rear 4. Plug the rudder servo Y harness into the rudder servo arm as shown below. Install the cable ball channel of the receiver and power up. Turn on links on bottom of the servo arm. transmitter to center rudder servos.
  • Page 28 6. Attach the ball link to the rudder control horn as 8. Finished rudder coupler assembly shown below. shown below. 7. Using the included adjustment wrench, adjust 9. Adjust the tension of the pull pull cables until the pushrod length to prevent the servo from they are tight.

  • Page 29: Tail Wheel Installation

    3. Place tail wheel steering tiller over the pre- Tail Wheel Installation drilled holes in the bottom of the rudder. 1. Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown.
  • Page 30 5. Place tail wheel strut over the pre-drilled holes 7. Mount the tail wheel strut using three wood in the bottom rear of the fuse. screws. 6. Place a drop of thick CA on tail wheel strut 8. Attach the steering spring to one side of the rud- mounting screws before inserting in the pre- der tiller.
  • Page 31 9. Use pliers to twist spring ends closed around the rudder and tail wheel tillers. 10. Repeat for opposite side tail wheel spring. Ad- just length and spring tension so that tail wheel is centered when rudder is centered. 11. Tail wheel assembly is complete.

  • Page 32: Main Landing Gear, Gear Cuffs, And Wheel Pant Installation

    MAIN LANDING GEAR , GEAR CUFFS, AND WHEEL PANT INSTALLATION 3. Align mounting holes in gear with pre installed Main Landing Gear Installation blind nuts in mounting plate of fuse. 1. Gather the landing gear parts as shown below. Note: Bolts have been offset to ensure correct in- (1) landing gear strut, (2) Gear Cuffs (2) wheels, stallation of gear.
  • Page 33 5. Bolt landing gear strut to fuse with (4) 8-32 bolts 7. Gather the (2) Landing Gear Cuffs as shown and washers. Ensure tapered edge of the gear below. They have been marked left and right for strut is facing toward the rear. the convenience of the builder 6.
  • Page 34 9. Use the (2) 4-40 mounting bolts and (2) bonded 11. Install the axle into the gear strut with nylon washers to secure the gear cuffs to the landing lock nut. Only snug tighten at this time. gear. 10. Finished landing gear cuff installation shown 12.
  • Page 35 15. Install the wheel and outer wheel collar. Use 13. Tighten the lock nut against the landing gear blue Loctite on the wheel collar set screw before strut to secure axel. final tightening. 16. Secure the wheel pant using the supplied 4-40 14.
  • Page 36 17. Final gear assembly with gear cover installed shown below.

  • Page 37: Engine Installation

    ENGINE INSTALLATION 3. Locate the laser cut engine mounting template Engine Installation for the DA-100. 1. The 100cc Extra 300 will accept a wide range of Note: If other engines are used the templates may engine types. Illustrations for a DA-100 be modified to fit you engine selection.
  • Page 38 5. Use a 1/4 drill bit to drill the engine mounting 7. Use a 1/4 drill bit to drill the ignition pickup holes in firewall. After drilling is finished, re- hole in the firewall. move template from firewall. 6. Mark a location for the ignition pickup to pass 8.

  • Page 39: Throttle And Choke Servo Installation

    9. Insert the (4) bolts through the engine mount and 11. Engine installation is now complete. install the engine standoffs and fender washers. Required distance from front of firewall to prop hub is 7 5/16”. Use correct amount of spacers and washers to achieve this distance.
  • Page 40 2. Attach the throttle pushrod to the engine throttle 4. Use a rotary cutting tool to cut out the throttle arm as shown. Ensure the servo and pushrod do servo mounting hole. not interfere with the standard muffler cans. Note: Cover engine with a towel or cloth or use masking tape to protect from any debris getting into the carburetor or cylinders.
  • Page 41 7. Assemble ball link to threaded coupler as shown 9. Cut the throttle pushrod to the proper length. below. 8. With the servo arm centered and the throttle arm 10. Gather the soldering tools as shown below. of the carburetor at half throttle, measure and mark the end of the throttle pushrod wire that Note: For best results we recommend a high will be inserted into the threaded coupler as...
  • Page 42 11. Solder the threaded coupler to the throttle 13. Attach the throttle pushrod with the 4/40 ball pushrod wire. links and secure. Power up the receiver and throttle servo and adjust pushrod for proper op- Note: Lightly sand end of rod for best bond. eration.
  • Page 43 3. Use a rubber grommet (supplied) to protect the 2. Assemble the rod as shown below. Follow the cowl from the manual choke pushrod. previous steps on pushrod installation. 2. Manual choke installation shown below.

  • Page 44: Ignition Installation

    IGNITION INSTALLATION Ignition module Installation 3. Position the ignition module inside the engine box to allow both of the spark plug leads to exit 1. Gather the supplied mounting hardware to be and properly connect to the engine without ex- used.
  • Page 45 6. Install the ignition module and the foam pad 8. Thread ignition connector through firewall and with a nylon tie as shown. connect ignition timing connectors with an Aeroworks Safety Clip. Ensure the connectors will not come apart from vibration or light ten- sion.
  • Page 46 9. Install the ignition switch as shown below. Fal- low the switch manufacturers directions for spe- cific switch mounting instructions. Note: Ensure switch does not interfere with mount- ing of wings.

  • Page 47: Fuel Tank Assembly And Installation

    FUEL TANK ASSEMBLY AND INSTALLATION 3. Assemble the fuel pick up line, rubber stopper Fuel Tank Assembly and metal end caps. As shown below. 1. Gather the fuel tank parts as shown below. A 1000cc (34oz) fuel tank has been provided. 2.
  • Page 48 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 49: Fuel Tank Installation

    Note: It is recommended you always use a fuel filter in the fuel line to the carburetor. Note: The fuel “T”, fuel filter and filler dot are not supplied, but are available through Aeroworks.
  • Page 50 4. Use nylon ties to secure fuel line. 6. Install foam rubber pad for fuel tank to rest on. Foam rubber will help prevent fuel from foam- Note: Gasoline will cause the fuel line to swell ing or getting air bubbles from engine vibration. over time.
  • Page 51 8. Mark and drill the fuel line exit hole in the bot- 10. Gather the fuel filler dot and drill bits as shown tom of the engine box. below. Note: We have supplied rubber grommets for you Note: We recommend you start with a smaller size to route the fuel line through to give a drill bit then increase the bit size to the finished professional look.
  • Page 52 12. Route the vent line on top of the fuel tank and 14. Route the vent line out of the cowl as shown secure with small nylon ties as shown. This will below. Using rubber grommet for a professional stop excess fuel from draining out the vent line finish.

  • Page 53: Standard Muffler/Cowl Installation

    STANDARD MUFFLER/COWL INSTALATION 3. Leave the canister tunnel cover off while flying. Standard Muffler Installation This will help provide better cooling for the en- gine. 1. Gather the standard muffler parts as shown: 2. Remove the canister tunnel cover as shown be- 4.
  • Page 54 5. Tape the provided card stock to the bottom of 7. Use the bottom mounting bolts to keep the tem- the fuse as shown below. plate secure. This will provide a consistent point of reference when marking and cutting the cowl. 6.
  • Page 55 9. Using a template enlarge the muffler exit hole 11. Cut out the holes on the paper template and rein- 1/4”. stall on the plane. Test fit the template, make any changes that may be needed at this time. 12. Re attach template to cowl and mark cut loca- tions for exhaust stack exit holes.
  • Page 56 Always check the operating temperature of your engine to prevent any damage from occurring. Aeroworks is not responsible for damages incurred from improper engine cooling. 16. Use a hobby knife to remove the covering around the hot air exit holes.

  • Page 57: Canister Muffler/Cowl Installation

    CANISTER/COWL INSTALLATION 2. Use a hobby knife to remove the covering Canister Installation around the hot air exit holes. Gather the canister muffler parts as shown: Shown: MTW TD75K Canister (Front Exit) 70mm Drop flex headers Teflon Couplers Mounting Clamps Using a covering iron seal the covering around 3.
  • Page 58 6. Assemble the canisters to the headers with the Remove the (4) Phillips head screws holding the Teflon coupler and clamps in accordance with canister hatch in place. manufactures instructions. 5. Gather and install the supplied silicone insula- 7. Slide the canisters into the canister tunnel as tors in the slots of the canister holding bracket as shown below.
  • Page 59 8. Secure the headers in place using the mounting 10. Install the cowling as shown below. The hot air bolts provided with your engine. Use blue Loc- exit holes have been pre-cut from the factory. tite to secure the bolts. 9.

  • Page 60: Tuned Pipe/Cowl Installation

    TUNED PIPE/ COWL INSTALLATION 2. Use a hobby knife to remove the covering Tuned Pipe Installation around the hot air exit holes. Gather the tuned pipe parts as shown: Shown: 100cc Greeves Tuned Pipes 70mm Drop flex headers Teflon Couplers Mounting Clamps Using a covering iron seal the covering around 3.
  • Page 61 6. Slide the pipes into the pipe tunnel as shown Finished hot air exit cut outs shown below. below. 5. Gather and install the supplied silicone insula- 7. Assemble the pipes to the headers with the Tef- tors in the slots of the tuned pipe holding brack- lon coupler and clamps in accordance with ets as shown below.
  • Page 62 8. Secure the headers in place using the mounting 10. Install the cowling as shown below. The hot air bolts provided with your engine. Use blue Loc- exit holes have been pre-cut from the factory. tite to secure the bolts. 9.

  • Page 63: Radio Installation

    RADIO INSTALLATION 1. Gather the receiver, battery, switch, regulator 3. Use (2) of the supplied Velcro straps to secure and mounting hardware as shown below. the receiver battery in place. Install the Velcro straps as shown below. 2. Install the receiver regulator following the 4.
  • Page 64 7. Apply baby powder or corn starch to antenna 5. Final battery installation shown below. wires to assist getting antennas into their guide tubes. 6. Install the receiver following the same method as 8. Push receiver antennas all the way into the pre the receiver battery.
  • Page 65 9. Tape the receiver antenna wires to the end of the antenna guide tubes and to the radio floor as shown. This will prevent the antenna wire from vibrating back out. 10. Install the receiver switch as shown below. Make sure that the placement of the switch will not in- terfere with the wing.

  • Page 66: Preflight Preparation

    PRE-FLIGHT PREPARATION 1. Gather the (4) 8-32 wing mounting bolts, (4) #8 3. Gather the (4) 4-40 stab mounting bolts and large rubber backed washers and (4) hair pins. (4) #6 small rubber backed washers. Note: Always check wing attachment bolts are securely tightened.
  • Page 67 5. Gather the (2) 4-40 and (2) 6-32 cowl mounting 7. Secure bottom section of cowl with bolts and (4) #6 small rubber backed washers. 4-40 x 16mm button head bolts and #6 bonded Mount the cowl using the cowl mounting bolts washers.

  • Page 68: Decal Installation

    DECAL INSTALLATION Optional Decal Package Available 3. Placement of optional decal package shown, in- 1. Decals supplied with the kit may vary from the cluded decals will differ. photos below. Decal application steps will be similar. Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squeegee or credit card, Windex or Application fluid like Rapid Tac.
  • Page 69 6. Remove backing from Clear transfer tape. 2. Placement of OPTIONAL decal package shown, included decals will differ. 5. Cut transfer tape to accommodate decal size. 7. Apply clear transfer tape over top of decal. Note: Transfer tape will be reused. DO NOT throw away any transfer tape until decal placement is complete.
  • Page 70 8. Press transfer tape to top of decal. 10. Spray model surface with application fluid, Windex or soapy water solution. 9. Peel backing from decal. 11. Spray back side of decal with application fluid, Windex or soapy water solution.
  • Page 71 12. Position decal in proper location. Application 14. Pull transfer tape from top of decal. Take care fluid will allow decal to be moved slightly. not to pull away or damage decal. 13. Using a plastic squeegee or credit card. Spread de- 15.

  • Page 72: Center Of Gravity / Control Throws

    CENTER OF GRAVITY - CONTROL THROWS Start at recommended CG until you are com- Center of Gravity fortable with the flight characteristics of the Warning, DO NOT skip this step! aircraft. You may find this a bit nose heavy at first but that is fine to start with.
  • Page 73 2. Elevator throw measured in inches at the widest 4. Elevator throw measured in degrees. Locate point of the elevator throw meter at widest point of the elevator. 3. Use the supplied flight control deflection meter . It is recom- to measure the throws in degrees 5.
  • Page 74 6. Gather the Rudder Throw Meter (Supplied) 8. Secure the tabs to the fin using scotch tape. As and scotch tape. shown below. Degrees are measured at the tip of the boost 7. Slide the throw meter under the rudder boost tab. tab as shown below.

  • Page 75: Control Throw Deflection Table

    Control Throw Deflection Table Low Rate High Rate Aileron 2.1/2” or 24˚ up 3 3/4” or 30˚ up 2 1/2” or 24˚ down 3 3/4” or 30˚ down Rudder N/A” or 25˚ left N/A” or 35˚ left N/A” or 25˚ right N/A”...

  • Page 76: Preflight Check List

    Preflight Check List Range check: Do a range check with and without Center of Gravity: Check CG is set properly. the engine running in accordance with the radio manufacturer instructions. If there is insuffi- Engine: The engine should run smoothly at all cient range or a large reduction with the engine throttle settings with smooth transition from running, do not fly until it is resolved!
  • Page 77 Spins upright and inverted • Flat Spins upright and inverted • Harriers upright and inverted • Water falls • Torque Rolls • Rolling circles • Rolling harrier The sky and your imagination are you only limits. FLY and ENJOY! AEROWORKS World Class Aircraft...
  • Page 78 Extra 300 CUSTOMER NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ __________________________________________________________________________...

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