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Related Manuals for 3DHS Extra 330-E
Summary of Contents for 3DHS Extra 330-E
- Page 1 95" Extra 330-E Assembly Manual Copyright 2017 Extreme Flight...
- Page 2 Please take a few moments to read this instruction manual before beginning assembly. We have outlined a fast, clear and easy method to assemble this aircraft and familiarizing yourself with this process will aid in a quick, easy build. Please read the following paragraph before beginning assembly of your aircraft! THIS IS NOT A TOY! Serious injury, destruction of property, or even death may result from the misuse of this product.
- Page 3 Discussions and brainstorming sessions began even before the merger of Extreme Flight and 3DHS. With the development, release and overwhelming enthusiasm for the Xpwr line of motors and in particular the Xpwr 60, this vanity project has now become reality! Extreme Flight is proud to present the 3DHS 95"...
- Page 4 Items needed for completion: ✓ Masking tape ✓ Hobby knife with #11 blades ✓ Thin and medium CA. We highly recommend Mercury M5T thin and M100XF medium formulas as well as the Mercury glue tips ✓ 30 minute epoxy. Pacer Z-Poxy is a long time favorite ✓...
- Page 5 Tips for Success: 1. Before starting assembly, take a few minutes to read the entire instruction manual to familiarize yourself with the assembly process. 2. Go over all the seams on the aircraft with a covering iron on a medium heat setting. Also, due to climate changes, wrinkles may develop in the covering.
- Page 6 Let's begin! Elevator Assembly 1. Locate the horizontal stabilizer/elevator assemblies as well as the composite control horns and base plates from the elevator hardware package. Trial fit the assembly into the slots in the elevator. 2. Trace around the base plate with a felt tipped marker.
- Page 7 3. Remove the horn assembly and use a #11 blade to remove the covering from inside the ink line you traced around the control horn base. 4. Wipe away the ink line with a cotton cloth or paper towel soaked in denatured alcohol.
- Page 8 5. Use sandpaper to scuff the portion of the horns and base plate that will be inserted into the elevator. 6. Apply 30 minute epoxy to the elevator slots using a zip tie to ensure the slots are filled will epoxy.
- Page 9 7. Apply a generous amount of epoxy to the bottom of the G-10 control horns and base plate. 8. Reinsert the assembly into the elevator and wipe away any excess epoxy with a cloth and denatured alcohol. Place a 3mm bolt through the horns to help insure proper alignment and set aside to dry.
- Page 10 Note: There are several methods and adhesives that can be used for installing the hinges. We will describe the way we do it as this method has proven itself over many years of model building. 9. Mix a generous batch of 30 minute epoxy. Use a zip tie or an old pushrod to thoroughly coat and fill the hinge holes on the stab with epoxy.
- Page 11 11. Make sure the hinge pins are centered in the hinge gap and that they pivot 90 degrees to the stab. 12. Now coat the other side of the hinges as well as the hinge holes in the elevator with epoxy and install the elevator onto the stab. Don’t forget to apply epoxy in the hinge holes on the stab before installing the stab to the elevator.
- Page 12 13. Use denatured alcohol and a cloth to remove all excess epoxy, especially on the hinge pin. Make sure you have full deflection in both directions – once satisfied with the results, set the surface aside to dry. After the hinges have dried thoroughly, pull on the surfaces to make sure they are properly secured.
- Page 13 14. Before installing the elevator servos, temporarily install the servo arms and electronically center the servos. Using the manufacturer supplied mounting hardware, install the elevator servo with the output shaft toward the rear of the stab and re-attach the servo arm. 15.
- Page 14 Wing Assembly 16. Locate the wing/aileron assemblies as well as the composite control horns and base plates from the wing hardware package. Following the same procedure as outlined with the elevator/stabs, install the control horns and hinges for both wings. 17.
- Page 15 Note: Before moving to the next step – it would be a good time to seal the hinge gaps with a strip of Ultracote or Blenderm tape. Be sure to fully deflect the control surface when sealing the gap to allow for full deflection once the gap is sealed. Also, take a few minutes to go over the wings with a trim iron on a medium heat setting to seal all the trim seams and remove any wrinkles in the covering.
- Page 16 19. Trail fit the landing gear fairings and when satisfied with fit secure with Goop style silicon glue. Tape in position until dry. 20. Locate the 2 axles, 2 locking nuts, 2 washers, 2 wheels, 4 wheel collars and 2 wheel pants.
- Page 17 22. Install each wheel pant using the supplied 3mm bolts and washers as shown in the picture below. As always, use blue Loctite on ALL bolts.
- Page 18 23. There are laser scribed marks for drilling for the motor mounting bolts for the Xpwr 60. Drill to accommodate 6mm bolts. If using another make of electric motor get the mounting template from the manufacturer and align on the laser inscribed crosshairs on the front of the motorbox.
- Page 19 25. There is a dedicated location with pre-installed blind nuts for mounting our recommended ESC, the Castle Creations Edge 160HV. Simply bolt it in place with 3mm bolts. Remember the Loctite! 26. Take a few minutes to secure the motor wires, battery leads and receiver lead and tidy up the installation to prevent chafing.
- Page 20 27. Locate the rudder, the rudder control horns and the 2 slotted base plates. Use sandpaper to scuff the bottom of the control horns as well as the side of the base plates that will attach to the rudder. If using a direct drive push-pull linkage (which is our recommended setup) only glue one set of horns in place on the right side of the rudder (pilot's perspective) in the lower position using the same procedure as you did with the elevators and ailerons.
- Page 21 There is a plywood jig included in the hardware package to help properly align the dual control horns if using a pull-pull setup. This makes achieving correct alignment a breeze. 29. Once your control horn installation has cured, mount the rudder to the fuselage using the same process as you did when gluing on the ailerons and elevators.
- Page 22 31. Attach a 36" EF 20awg servo extension to your rudder servo and secure with an EF Servo Safety Clip. Install the rudder servo in the rear of the fuselage as shown if using a direct drive rudder actuation setup and assemble the linkage as shown with the provided hardware.
- Page 23 33. Install the rudder servo in the designated location in the rudder tray. Electronically center the servo and install the EF 4" pull-pull arm. Secure the cables to the arm as show using 3mm bolts. As you'll notice in this picture we used the SWB Pull-Pull Tensioning Kit which makes getting the proper tension on the cables very easy and is a worthwhile investment.
- Page 24 35. The cowl has a unique method of mounting that allows easy installation and removal. It is secured with 3 3mm bolts, 2 on the lower external portion of the cowl and one mounted from the interior of the fuselage. The cowl hangs on 2 hooks and is secured at these 3 locations.
- Page 25 36. Attach a 36 inch EF 20 awg servo extension to each elevator servo lead. If you plan to remove the stabs for transport, you will need to use 48 inch extensions. Secure with EF Servo Safety Clips or heat shrink tubing. Slide the stab halves onto the carbon fiber stab tube and secure with a 3mm bolt and washer inserted through the mounting tabs and into the pre-mounted blind nuts.
- Page 26 39. There is plenty of room inside the fuselage to secure all of your servo extensions and battery wires. Take a few minutes and tidy up your installation and make sure everything is secure and protected from chafing. Here is a picture of the interior of our Extra to show how we secured the internals.
- Page 27 20 degrees low rate, 50% exponential; all you can get for high rate, 50-60% exponential. This completes the assembly of the 3DHS 95" Extra 330E. As a final step clean the entire aircraft with glass cleaner, then apply a coat of spray-on wax and buff the finish to a high gloss.