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3D Hobby Shop Extra 300 Assembly Manual

3dhobbyshop arf rc 87" shp aircraft assembly manual

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3DHobbyShop.com
Extra 300 SHP 87" Assembly Manual
Thank you for purchasing this 3DHobbyShop ARF RC aircraft. If you have any issues, questions,
concerns or problems during assembly, please contact our tech department at:
Info@3DHobbyShop.com
or 1-830-990-6978 10am-5pm Central M-F
SAFETY in Assembly
During assembly of this aircraft, you will be asked to use sharp knives, hot irons, and hobby adhesives.
Please follow all safety procedures recommended by the manufacturers of the products you use, and
always follow these important guidelines:
ALWAYS protect your eyes when working with adhesives, knives, or tools, especially power tools. Safety
glasses are the best way to protect your eyes.
ALWAYS protect your body, especially your hands and fingers when using adhesives, knives, or tools,
especially power tools. Do not cut toward exposed skin with hobby knives. Do not place hobby knives on
tables or benches where they can roll off or be knocked off.
ALWAYS have a first-aid kit handy when working with adhesives, knives, or tools, especially power tools.
ALWAYS keep hobby equipment and supplies out of the reach of children.
SAFETY in Flying
ALWAYS fly your aircraft in a safe area, away from spectators.
ALWAYS fly your aircraft in a safe manner, within your control.
NEVER fly too close to yourself.
ALWAYS wear eye protection while operating your model aircraft.
ALWAYS keep your hands and body clear of propellers.
ALWAYS observe lipoly battery safety procedures.
ALWAYS handle gasoline in a safe manner.
ALWAYS perform a ground test and range check of your radio system before flying.
REQUIRED ITEMS
30 Minute Epoxy Glue (NOT 5-minute Epoxy)
Polyurethane Glue for hinging if desired
Hobby Knife
Soldering Iron
Phillips Screwdriver
Set Metric Allen Wrenches
Small Pliers
Wire Cutters
Rubbing Alcohol
Paper Towels
Blue Loctite thread-locking adhesive
Dremel-type rotary tool
Small adjustable wrench or wrench set

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Summary of Contents for 3D Hobby Shop Extra 300

  • Page 1 3DHobbyShop.com Extra 300 SHP 87” Assembly Manual Thank you for purchasing this 3DHobbyShop ARF RC aircraft. If you have any issues, questions, concerns or problems during assembly, please contact our tech department at: Info@3DHobbyShop.com or 1-830-990-6978 10am-5pm Central M-F SAFETY in Assembly During assembly of this aircraft, you will be asked to use sharp knives, hot irons, and hobby adhesives.
  • Page 2 Developer’s Notes I’m exceptionally proud to be able to introduce the new 3D Hobby Shop 87” 50cc Extra 300 SHP. It is the culmination of over a year of in depth aerodynamic, airframe, and component development. From the beginning our primary focus was creating not only a World-Class 50cc sized aerobatic model, but arguably the premier 50cc aerobatic model on the market today.
  • Page 3 IMPORTANT NOTE: 3DHS Recommends ONLY High-Torque, Digital, Metal-gear Servos for this aircraft. Suitable part numbers include Hitec HS-5955TG, JR 8611A, and JR 8711A. DO NOT attempt to use nylon-geared servos on this airplane. Assembly Instructions UNPACK Unpack your airplane and examine the components. Check for damage of any kind. If you find any damage, contact 3DHobbyShop and report the damage.
  • Page 4 Although the holes are already drilled, you may need to open up the end of the hole slightly, using either a drill bit or a grinding stone on a dremel rotary tool. This is to allow the center section of the hinge point to fit easily in-between the stabilizer and elevator.
  • Page 5 Apply 30 minute Epoxy glue to the inside of the holes in one surface. In the following photo, we are using the end of a nylon zip-tie to apply the epoxy inside the hole. Insert the hinge points into one side, and carefully align them so that they sit perfectly centered in their holes.
  • Page 6 Clean up any excess epoxy which comes out of the holes with a paper towel and rubbing alcohol. Make sure the hinge points are properly centered and aligned, and set the surface aside to allow the glue to cure. Once the glue has cured, repeat the procedure to install the opposite surface. Push the other surface up tight against the first one;...
  • Page 7 Sumo Glue for Hinges While we recommend the use of high-quality Epoxy during hinge assembly, another good alternative is Sumo brand water activated adhesive. It dries clear, dries quickly, and doesn’t need to be mixed prior to use. Here are a couple of hints for using Sumo glue in hinge assembly applications. 1.
  • Page 8 Elevator and Aileron Control Horns Your Extra features phenolic CNC-cut control horns. The slots for the horns are pre-cut into all of the control surfaces. You will need to remove the covering over each of these locations. The best way to trim covering on this aircraft is with a hot pencil-tip soldering iron. This method gives a clean cut and also seals the edges of the covering at the cut line.
  • Page 9 5. Remove the horn and use the soldering iron to trim the covering just inside the square mark you made with the pencil.
  • Page 10 6. The control horns will need to be trimmed as shown. Use a dremel tool with a sanding drum attachment. Do this work in a well-ventilated area and use eye protection! 7. Apply 30-minute epoxy liberally to the bottom of the horn and to the wood of the control surface. Install the horn.
  • Page 11 to the center of the two horn pieces, and install into the rudder. Use alcohol to clean any excess epoxy and temporarily insert two 3mm bolts through the holes in the horn to ensure alignment while the glue cures. Trim the rudder horn outer holes away (as on the other horns) if necessary to match the width of your rudder servo horn.
  • Page 12 Fuselage and Landing Gear Take your soldering iron and remove the covering over the necessary locations in the fuselage as shown: NOTE: The large holes in the bottom of the fuselage are for the canister exhaust outlet and cooling cover. You do not need to remove this covering for electric power applications, and it is optional for gas engines with stock or pitts mufflers.
  • Page 13 Measure back 2 inches on the bottom of the rudder from the hinge line, and drill a 3/32” hole into the bottom of the rudder. Take the 1” threaded stud and screw one of the ball-joints onto the stud as shown. Place epoxy or sumo glue onto the stud and screw the stud and ball-joint into the rudder as shown.
  • Page 14 NOTE: Tailwheels can be easily damaged by rough fields or rough flying. Replacement tailwheel assemblies are available, and we have provided a hatch on the airplane, as shown below, for access to the tailwheel mounting plate. This hatch is also useful if you wish to add tail-weight to your aircraft.
  • Page 15 Access this hatch by removing the covering as shown, the cover is included and is retained by four 3mm screws. Locate the wheel axles and nuts and attach to the landing gear as shown. Install the inner wheel collar, wheel, and outer wheel collar. Use a dremel tool with cutoff wheel to trim away the excess axle length as needed.
  • Page 16 Install landing gear onto the bottom of the fuselage using socket-head bolts, washers, and locknuts as shown. Afterward, use epoxy or CA glue to install the landing gear cover-plate onto the bottom of the landing gear mounting area. The wheel pants are molded with a narrow axle slot. We suggest widening the axle slot in the pant with a dremel tool as shown.
  • Page 17 Slip the pants down over the wheels and axles, fasten to the landing gear legs with 2 3mm bolts. Pull-Pull cables The pull-pull cables for the rudder are assembled as shown in the following diagram:...
  • Page 18 Scott’s Tip – There are a lot of different opinions on the correct sequence for this step, so I'll add that this is just my technique: I prefer to use two crimps per surface attachment at both the servo and rudder. I've always had a hard time trying to get the line tight and also run through the initial link a second time.
  • Page 19 Assemble the pull-pull ends and ball joints onto the rudder servo arm as shown, and attach the pull-pull cable using the same technique as before. Adjust the lengths of the pull-pull cable to get good tension (just snug, with no sag, and no play in the rudder –...
  • Page 20 Using threadlocker on all mounting hardware, attach your motor to the firewall. It is a good idea to use large washers on the back of the firewall to spread the load. Loctite all mounting fasteners!
  • Page 21 We have provided more than enough fasteners to secure the firewall to the engine box, if one of your engine-mounting bolts interferes with one of the firewall attaching screws, remove the firewall attaching screw if necessary – the engine-mounting bolt will take over its job, provided that your washer overlaps the aluminum angle-iron bracket.
  • Page 22 Mount the ignition box using a piece of foam rubber between the box and airframe to isolate the box from vibration. Fuel Tank We recommend a two-line system for fuel, installed as follows: Assemble the fuel tank as shown, using small nylon zip-ties as hose clamps to retain the flexible fuel tubing onto the rigid metal tubing.
  • Page 23 The fuel-feed line runs from the tank, to either a Du-Bro gasoline filler valve or a Y-connector and fuel dot, and then to the carburetor.
  • Page 24 Scott’s TIP - To eliminate fuel loss during aerobatics, I run the fuel vent line aft of the back end of the fuel tank. I've found the easiest method is to use small zip-ties to create a housing for the vent lines to run in. See photos: Run the vent line into the cowl and out the bottom as shown:...
  • Page 25 Exhaust Canister Muffler Installation The Extra includes pre-fabricated mounts for the MTW TD-75K short canister muffler, available from Desert Aircraft. I Slide the canister part-way into the canister tunnel, you will need to twist the can as it goes in to clear the fuselage former.
  • Page 26 Slip the canister mounts onto the canister from the rear, F3 first, and then F4. Note that you will need to trim F3 to clear the landing gear braces as needed to allow F3 to slide fully forward into position. When you have F3 and F4 fully into position as shown, tack them in place with CA glue and then apply epoxy to permanently mount them.
  • Page 27 In this installation, we have used a “Medium Drop” flex header from Desert Aircraft to attach the DL-50 engine to the canister. Pre-drill the screw holes as shown, and use 6 wood screws to attach the canister-cover plate and 4 screws to attach the outlet plate.
  • Page 28 Cowl Installation The Extra cowl must be cut to allow clearance for the cylinder, spark plug, and muffler (if canister is not used) of the engine. We recommend the use of a dremel rotary tool for this step. Use eye protection and work in a well-ventilated area.
  • Page 29 Transfer your cutout dimension onto the cowl, as shown, use the tracing of the alignment tabs for alignment. Cut out this shape with the dremel. Attach the cowl to the fuselage using three 3mm bolts from the back of the fuselage former and 2 wood screws from the bottom through the alignment tabs.
  • Page 30 Elevator Servos and Horizontal Stabs Mount your elevator servos inside the horizontal stabilizers as shown. Center the servos, and slide your servo arms onto the servo output splines. NOTE: for full 3D throws, 2” servo arms are recommended for the elevators. Rotate the servos and arms as necessary to access all fasteners to lock the arms in-place.
  • Page 31 The Extra includes a fiberglass tube installed into the fuselage to assist in cleanly routing your elevator servo extensions into the rear of the fuselage. It may be helpful to tape the extensions onto a piece of wire and feed the wire through the tube, as shown. Install the horizontal stabilizers onto the fuselage using the carbon-fiber tube spar.
  • Page 32 Aileron Servos Remove the covering over the servo openings in the bottom of the wings. Attach an 18” extension to the aileron servo and secure the extension as before. A pull-string is provided to help guide the extension through the wing.
  • Page 33 Install the servo with the servo head toward the front of the airplane, and attach the pushrod as you did for the elevator. Wing Attachment The wing attaches to the fuselage with two nylon thumb-screws per side. Extra, spare thumb screws are included in the kit.
  • Page 34 recommend non-stick cooking spray or silicone spray-lube for this job. Your wings will be an especially snug fit onto the tube the first several times you install them. Go slowly and patiently to prevent damage the first several times. Radio Installation Notes We highly recommend Smart-Fly products (http://www.smart-fly.com/) to assist your radio installation.
  • Page 35 To mount your electric motor, use one of the gasoline mount templates to mark the thrust-line center on the firewall, and then create a mounting template for your particular motor mount on paper. Match up the center of your template with the thrust-line center on the firewall, and mark your hole locations. Be sure to use blue Loctite on all of your fasteners.
  • Page 36 The canopy hatch is held onto the fuselage with 3mm nylon thumbscrews. These thumbscrews require no tools to install or remove and are very convenient – but because they are plastic they will not last forever. Inspect them frequently – spares are included in your kit. You can also use a 3mm allen-bolt and washer if desired.
  • Page 37 When flying with the SFGs installed, it is possible to scrape them if you dip a wing on landing. For this reason, we recommend protecting the bottom edge of the SFG with some clear packing tape. Spare SFGs are also available.