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AJ Aircraft 73” AJ Laser 230z Assembly Instructions Manual

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73" AJ Laser 230z
Assembly Instructions

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Summary of Contents for AJ Aircraft 73” AJ Laser 230z

  • Page 1 73” 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  Components 2x 4-6s 3300-4400mah lipos  21x10 Prop (Falcon recommended)  DA-35 or equivalent gas engine  Servo Extensions:  Hacker A60-5S Motor or equivalent  2x 6”  Castle Ice 100 Amp ESC or equivalent ...

  • 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 Section 1 Fuselage — 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. Tip: It is a good idea to put a drop of thin CA in the holes after inserting and removing wood screws to harden the wood &...

  • Page 6: Main Landing Gear

    Main Landing Gear 3) Open the landing gear bag and sort the bolts, axles and other parts. 4) Place the landing gear onto the fuse with the THINNER ANGLED edge reward (the gear is shaped like an airfoil). Secure with 4 bolts an washers into the pre-installed blind nuts in the fuselage.
  • Page 7 7) Remove the axles, wheels, wheel collars, wrench and lock nuts from the bag. Slide the wheel on the axle and secure with a wheel collar. 8) To install wheel pants, slide over tire and align horizontally to fit in the wheel pant recess. Using the provided wrench, secure the axle to the landing gear with a washer and lock nut.
  • Page 9 Section 2 Fuselage — Elevator/Rudder 9) Remove the fuselage and using a sharp knife, remove the covering from the areas to allow the anti-rotation pins, wing tube, aileron extensions and wing capture bolt to pass through. 10) Also remove the covering exposing the horizontal stabilizer slot on both sides, and the hole for the elevator servo on the LEFT side of the fuselage.
  • Page 10 12) Loop a string to a measuring tape over the hatch latch. Adjust the stab until you get equal measurements to both the left and right corners. Extra time spent here will go a long way to improve the flight characteristics of this airplane. 13) Once the stab is centered and squared up, secure it with thin CA on both sides, top and bottom.

  • Page 12: Install The Elevator

    Install the Elevator 14) 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. 15) Assemble the horn in the order of bolt, washer, control horn, ball link, control horn, washer, lock nut.
  • Page 13 16) 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. 17) Remove the assembly and use a sharp blade to cut approx. 1/16” in from your line and remove the covering. Use caution to...
  • Page 14 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. 18) Scuff the bottom portion of each horn and the base plate with sandpaper. Thoroughly spread 30 minute epoxy or gorilla glue on both sides &...
  • Page 15 20) Test fit all hinges into elevator and horizontal stabilizer to make sure alignment and position is correct. Make sure there is enough clearance between the elevator joiner so as not to rub on the fuselage. Should there be clearance issues, you may touch it up with a Dremel and a sanding drum.
  • Page 16 22) Take the left elevator and thoroughly spread epoxy or gorilla glue over the hinge halves up to the last knuckle and inside each hole on the left stab. Put each hinge into its’ hole and slowly press in until about 1/4” is left. Remove any excess epoxy with a paper towel and denatured alcohol.
  • Page 17 25) Install the servo with the screws that came with it. Use a 1.5” heavy duty servo arm. Tip: Drill pilot holes for the screws and then install the screws. Remove the screws and the utilizing thin CA, place the CA in the screw holes and around the screw holes and let dry.

  • Page 18: Install The Rudder

    Install the Rudder 27. Carefully cut the covering from both sides of the rudder exposing the 2 slots for the control horn. 28. Lightly sand the middle of both control horns on both sides and test fit it into the slot. You may need to round the outside mid- dle corners.
  • Page 19 Push-Pull Rudder Setup 33. If using push-pull, you will need to cut open the covering on either side of the fuse directly below the stab tube hole. 34. Mount the servo with the output shaft towards the tail and a 1.5” servo arm. Use the supplied turnbuckle and ball-link hard- ware to connect the servo to the rudder using the same process as the elevators.
  • Page 20 40. Secure the rudder by lightly taping it to the vertical stab. 41. Make sure your servo is electronically centered. You’ll want to have the servo powered via a servo tester or the receiver until the pull-pull assemblies are completed to ensure accuracy. 42.
  • Page 21 Section 3 — Wings 41) Utilizing a hot knife or fresh #11 blade, carefully cut and remove the covering exposing the servo pocket located on the under- side of each wing panel. 42) Carefully locate and cut the aileron control horn slots on the underside of each aileron. Shine a flashlight through the opposite side if you have trouble locating the slot.
  • Page 22 paying close attention to orientation. Then glue the base down. 47) Clean any excess epoxy using a paper towel soaked with denatured alcohol and set aside to cure. 48) Attach 6” servo extensions onto the servo leads and using the string inside the wing tape the extension to the string and pull the extension through the wing.
  • Page 23 Section 4 Motor/ESC & Cowl 25) Now let’s get some power under the hood. The firewall center lines have been pre-scribed for you. Drill templates have been provided. Otherwise, use the manufacturers mounting template and tape it to the engine box, lining up the vertical line on the template with the RIGHT vertical line on the firewall.
  • Page 24 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 firewall. 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 25 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 26 33) Cut the cowl as needed to clear the engine head, mufflers as well as extra for exiting air. Add baffling with balsa or craft foam as desired to direct airflow over the engine heads and out the exit in order to keep your engine running cool & happy. Baffling is not required, but is always a good idea.
  • Page 27 53. Secure the X mount to the motor using the 4 small bolts supplied with the motor. Reminder—ALL bolts in this section should get a drop of blue Loctite! 54. If your motor did not come with bullet connectors installed, solder those on now. Don’t forget to use heat-shrink on each one to prevent shorts.
  • Page 28 of the fuselage far enough forward that the paper covers the 2 hardwood mounting blocks on each side. 60. Mark the location of each hole on the paper. Use a flashlight if needed to help you locate the holes. Poke a small hole in the paper to ensure you’re lined up.
  • Page 29 63. Secure the cowl using the 4 small wood screws provided. Remove the screws and apply a few drops of thin CA to harden the wood and threads. Then, remount the cowl. 64. Secure the prop and spinner. SFGs (Optional) 65.

  • Page 30: Radio Installation & Setup

    Section 5 Radio Installation & Setup Your receiver can be mounted anywhere in the airframe. Adding a small piece of wood across the fuselage behind the wing tube works pretty well for this airframe. 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 31 Enjoy your new plane! We at AJ Aircraft sincerely hope you enjoy flying the 73” 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-...