EXTREME FLIGHT Turbo BushMaster 120 User guide

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120”TurboBushmaster

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Copyright2018ExtremeFlight

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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!

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THISISNOTATOY!Seriousinjury,destructionofproperty,orevendeathmayresultfrom
themisuseofthisproduct.ExtremeFlightRCisprovidingyou,theconsumerwithaveryhigh
qualitymodelaircraftcomponentkit,fromwhichyou,theconsumer,willassembleaflying
model.Itisbeyondourcontroltomonitorthefinishedaircraftyouproduce.ExtremeFlight
RCwillinnowayacceptorassumeresponsibilityorliabilityfordamagesresultingfromthe
useofthisuserassembledproduct.ThisaircraftshouldbeflowninaccordancetotheAMA
safetycode.ItishighlyrecommendedthatyoujointheAcademyofModelAeronauticsin
ordertobeproperlyinsured,andtooperateyourmodelatAMAsanctionedflyingfields
only.IfyouarenotwillingtoacceptALLliabilityfortheuseofthisproduct,pleasereturnit
totheplaceofpurchaseimmediately.
ExtremeFlightRCguaranteesthiskittobefreeofdefectsinmaterialsandworkmanshipfor
aperiodof30DAYSfromthedateofpurchase.Allwarrantyclaimsmustbeaccompaniedby
theoriginaldatedreceipt.Thiswarrantyisextendedtotheoriginalpurchaseroftheaircraft
kitonly.
ExtremeFlightRCinnowaywarrantiesitsaircraftagainstflutter.Wehaveputtheseaircraft
throughthemostgruelingflighttestsimaginableandhavenotexperiencedanycontrol
surfaceflutter.Properservoselectionandlinkageset-upisabsolutelyessential.Inadequate
servosorimproperlinkagesetupmayresultinflutterandpossiblythecompletedestruction
ofyouraircraft.Ifyouarenotexperiencedinthistypeoflinkageset-uporhavequestions
regardingservochoices,pleasecontactusat[email protected]or770-887-1794.It
isyourresponsibilitytoensuretheairworthinessofyourmodel.
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ExtremeFlightandLegacyAviationareexcitedtoannouncethereleaseofthelongawaited
120"Bushmaster!ThebrainchildofCodyWojcik,thisdesignbuildsonthelegacyofthe
original84"and65"versionswhichhavebecomemusthaveadditionstothehangarsofRC
enthusiastsaroundtheglobe.Renownedforitsabilitytobebotha"relaxingbutnever
boring"sportmodelaswellasafullycapablebushstyleaerobat,theBushmasterdesignhas
wonlegionsoffanswhosimplywantagreatflyingmodelwithauniqueappearanceand
style.NowLegacyAviationdeliversthenextstepinthisseriesaimedatthegiantscale
enthusiast,the120"Bushmaster!DesignedaroundtheXpwr60brushlessoutrunnerand
theDA-70twincylindergasengine,theBushmasterdeliversaboutasmuchfunascanbe
hadwithanRCaircraftwitheitherchoiceofpowerplant.We'verecentlybeenflyingour
DA-70poweredversionwitha2into1headerandsinglecanistermufflersetupwhich
deliversquietconsistentpowerandlongflighttimes.OfcoursetheXpwr60versionwitha
12S5000+mahbatterysetupprovidesexcellentpowerandiscleanandquiet.Whichever
powersystemyouchoose,youarecertaintohaveamostfulfillingflyingexperience!

TheBushmasterfeaturesalightweightbuiltupbalsaandplywoodairframewith
strategicallyplacedcompositereinforcementstoaddstrengthandrigidity.Itfeaturesa
carbonfibermaingearandtailwheelassemblyalongwithcarbonfiberwing,staband
ruddermountingtubesandtwogorgeousUltracote(Oracover)colorschemes.Anexpertly
paintedfiberglasscowlisstandardfarealongwithaprolevelhardwarepackage.An
optionalfloatkitisalsoavailableforwaterbasedoperations.

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Ultracote/OracoverColorCodes:

White/Blue/Silverscheme:UltracoteHANU870White,HANU885MidnightBlue,HANU881
Silver.Oracover21-010White,21-052DarkBlue,21-091Silver.

Yellow/Black/Greyscheme:UltracoteHANU872BrightYellow,HANU874Black,HANU882
LightGrey.Oracover21-033CadmiumYellow,21-071Black,21-011Grey.

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Recommendedaccessories:

DesertAircraftDA-70gasengineorXpwr60ccbrushlessoutrunner

MTWTD110Hrearexhaustcanisterwith60mmdrop,2-into-1headerandcouplerkit

24-34ounceFlowmastergastank

EFAnodizedfueldot

EFBluefuelline

52"EFservoarms(ailerons,flaps,rudder)

21.5"EFservoarms(elevators)

11"EFservoarm(throttle)

11.25"EFlightweightservoarm(tailwheelsteering)

BlazingStarDA-70mount

BlazingStarXXLStandoffsetforXpwr60

CastleCreations160HVESC

Falcon24x9carbonpropforDA-70

Xoar24x10or24x12woodorFalcon26x8carbonpropforXpwr60

Qty.2–EF6inch20AWGservoextension(Flaps)

Qty.3–EF24inch20AWGservoextension(Ailerons,throttle)

Qty.3-EF36inch20AWGservoextension(Elevators,tailwheelservo)

Qty.1–EF48inch20AWGservoextension(Rudder)

2setsEFMPXMulti-wireservoplug(2wireversion)

EFServoWireSafetyClips

4"EFCarbonFiberspinner

7hightorquemetalgearservosforcontrolsurfaces(MKS1220,MKS777A+orequivalent)

1highspeedservoforthrottle(MKS1250)

1metalgearminiservofortailwheelsteering(Hitec5245,7245)

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Let’sbegin!

1.Locatethe2wingpanelsaswellastheG10aileronandflapcontrolhorns.Usesandpaper
toscufftheportionofthecontrolhornthatwillbegluedintothesurface.Foramore
finishedlookyoumaywishtopaintyourcontrolhornsbeforeinstallation.Donotpaintthe
portionofthecontrolhornthatwillglueintothecontrolsurface.
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2.Usingasolderingironorasharphobbyknife,removethecoveringfromtheslotsforthe
aileronandflaphorns.Placethecontrolhornsintothebaseplate.Dryfitthehornsinto
theirrespectiveslotsandtrimanydebrisfromtheslotuntilthecontrolhornseatsproperly
againstthecontrolsurface.Sandawayanyportionofthebaseplatethatmayextend
beyondtheedgeofthebevel.Oncesatisfiedwithfitremovethecontrolhornsanduseyour
hobbyknifetoremovethecoveringthatisunderthebaseplateforbestglueadhesiontothe
surface.

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3.Applyagenerousportionof30-minuteepoxytotheaileronandflapcontrolhornslots
andtothescuffedareaofthecontrolhorns.Itmaybehelpfultouseaziptietopushthe
epoxyintotheslots.

4.Assemblethecontrolhornsandballlinksasshownandinstallthecontrolhornsinto
theirrespectiveslots.Wipeawayanyexcessepoxywithapapertowelorclothsoaked
withdenaturedalcohol.

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5.Inthesenextstepswewillinstallthehinges.Pleasetakeafewmomentstofamiliarize
yourselfwiththisprocessifyouhavenotinstalledhingepointsbefore.
Thereareseveralwaystodothisandseveraladhesivesyoucanuse.Wewilldescribethe
waythatwedoit,asthismethodhasprovenitselfovermanyyearsofmodelbuilding.If
youarenewtothistypeofhingingprocess,thenIrecommendthatyouinstallasingle
hingefirstjusttoacquaintyourselfwiththismethod

Beforestartingyouwillneedtogatherafewitemstoaidyouasyouproceed.
A. 30MinuteEpoxy
B. Ashortlengthofpushrodorsmalldowel.
C. Arollofpapertowels
D. DenaturedalcoholorAcetone
E. HobbyKnife
F. Teflonlubricant

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6.Locateawingpanelandseparatethecontrolsurfacesfromthemainwingandremove
thehinges.

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Mixupagenerousbatchofepoxyanduseapieceofpushrodordoweltoapplythe

epoxytothehingehole.

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8.Applyepoxytothebarbedsectionofthehingeononesideandinsertitintothehole
untilthecenterofthehingeiscenteredonthehingeline.Usingapapertowelsoaked
withacetoneordenaturedalcoholwipeawayanyepoxythathasbeensqueezedoutof
thehole.

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9.Makesurethehingecanmovefreelyandthatthepinisalignedproperlybeforethe
epoxysets!Whenyouaresatisfiedwiththeresultssetthesurfaceasidesothatthe
epoxywillpoolaroundtherearofthehinge.Whenyouarecomfortablewiththis
processyoushouldbeabletodoonesideofasurfaceperbatchofepoxy.Repeatthe
processtoattachthesurfacestoeachwing.Thereshouldbeaslittlegapaspossible
whilestillallowingmaximummovementofthecontrolsurface.

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10.Asafinalstepbeforesettingthewingasidetodry,doafinalcleaningofthehinge
knuckleswithapapertowelsoakedwithdenaturedalcoholoracetonetoremoveany
epoxyresidue.Ifyoufindanyofthehingesarestiffafterdrying,applyadropofacetone
toeachhingewithaQ-tipandmovethesurfacebackandforthseveraltimestoloosenit
up.AsafinalstepItypicallyapplyacoupledropsofTeflonlubricanttoeachhinge.This
isavailableatmosthomeimprovementandhardwarestores.

11.Youwillneedtoattacha24inchservoextensiontoyouraileronservotoreachthe
wingroot.Theflapservowirewillrequirea6inchextension.Securetheextensionsto
theservoleadswithheatshrinktubingoraservowiresafetyclip.
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12.Usethemanufacturersuppliedmountinghardwaretoinstallthewingservoswith
theoutputshafttowardtheTRAILINGEDGEofthewing.Electronicallycenterthe
servoandinstall2inchservoarmsontotheservospline.Theservoarmsshouldbe
paralleltothehingelinewhencentered.Itisveryimportantthatyouusethesame
lengthservoarmsforbothflapandaileronservos.

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



13.Foreaseoffieldassemblywehighlyrecommendusing2setsoftheExtremeFlight

MPXMulti-wireservoplugs.Attachthesetotheservoextensionsprotrudingfromthe

wingforafastandeasysingleplugsolutiontowingservoconnections.Besuretosecure
theMPXplugleadsothatitcannotfloparoundinsideofthewing,possiblycausingthe
plugtopulloutofthereceivingsocket.






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9

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14.Usethesuppliedballlinks,turnbucklepushrods,3mmbolts,washersandnutsto
assembletheaileronandflaplinkagesandsecuretotheservoarmandcontrolhorns
asillustratedinthefollowingphoto.Boththeaileronandflaplinkageareassembled
thesameway.



15.Locatethewingfencesandtrialfitontothewing.Somesandingmayberequired
forbestfit.Werecommendgluingthefencesinplacewithepoxy.Usetapeorclamps
toholdthefencesinplacewhiletheepoxycuresmakingsuretheyareperpendicular
tothesurfaceofthewing.Twostripsoftapeplacedparalleltothefenceswillkeep
excessepoxyfromgettingonthewingsurface.

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10

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11

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16.Locatethelandinggearcomponentsandtheassociatedfastenerpackageformthe
hardwarekit.Securethecarbonfiberlandinggeartothefuselagewiththeprovided
4mmsocketheadcapbolts,washersandlocknuts.



17.ApplyabeadofGoopadhesivetothecarbongearandslidethelandinggearfairing
intopositionagainstthebottomofthefuselage.Securewithtapeuntiltheadhesive
dries.

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12

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18.Attachtheaxlestothecarbongearwiththesuppliedwasherandlocknut.

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

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13

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19.Fileaflatspotontheaxlesforthewheelcollarsetscrewstoseatagainst.Securethe
wheelintopositionwithacollarplacedoneachside.BesuretouseLoctiteonall
fasteners!

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14

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20.Assemblethetailwheelasshown.Itishighlyrecommendedthatyouflieaflatspot
atthelocationthateachsetscrewwillseatandagain,applybluethreadlockcompound
toallscrews.



21.Installthetailwheelassemblyontothebottomrearofthefuselagewiththeprovided
3mmboltsincludedinthehardwarepackage.Thisstepwillallowustoturnthefuselage
overandplaceitonits"feet"whichwillallowabetterpositiontoinstalltheengine.

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15

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22.Flipthefuselageandletsinstallourpowerplantofchoice.Drill41/4"holesatthe
designatedlocationforyourmotor/engine.



23.IfusingtheXpwr60itishighlyrecommendthatyouusetheBlazingStarXXLStandoff
Settoachieveproperspacingwithminimalhassle.IfusingtheDA-70theBlazingStar
mountmakesproperenginepositioningabreeze!

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16

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24.Inthepreviousphotoyoucanalsoclearlyseetheinstallationofthe2-into-1
header/canistersetupandthethrottleservoinstallation.Hereareafewmorepicsofthe
enginesetupincludingtheignitionmountinglocationandthecoolingcutoutsonthe
bottomofthecowl.

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17

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25.TheBushmastercowl,becauseitlacksanyairinlets,requiressomecreativecooling
methodstokeepourpowersystemrunningproperly.Inthepreviousphotoyoucansee
thecutoutswemadeinadditiontotheairdamweinstalledtopullairovertheengine
andoutofthecowl.Thiswasfabricatedfromapieceofaluminumflashingpurchased
fromalocalhomeimprovementstore.Properventilationisamust!!!!

18

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26.Inadditiontoopeningupthebottomofthecowlwealsomadesurethedummy
exhauststackscontributedtopullingairoverthecylindersandremovingitfromthecowl
byopeningthecowlandexhauststacksbeforegluinginplace.Removeasmuchpaintas
possiblefromthegluingsurfaceaspossibleandglueinplacewith30minuteepoxy.



27.Beforefinalinstallationofthecowlanddependingonyourchoiceofpowersystem
installeitheryourgastankonthetank/batterytraywithplumbingortheESC.

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19

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28.Installthelowercowlhalf,withthe43mmboltsprovidedinthehardwarepackage,
followedbythetoppieceofthecowlwith4more3mmbolts.Inthisphotowehave
addedtheEFanodizedwashersforatouchofbling.



29.Locatethestab/elevatorsetalongwiththeelevatorcontrolhorns.Usingthesame
methodastheailerons,hingebothstabhalvesandinstallthecontrolhornsinthe
locationshown.

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20

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21

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30.Installtheelevatorfenceswiththeprovided3mmboltsinsertedthroughthefence
andintothepre-installedblindnutsinthestab.





31.Slidethecarbonfiberstabtubeintothesleeveinthefuselagerear,thenslideboth
stabsontothetubeandsecurewith23mmboltsandwashersinsertedthroughthetabs
atthestabrootandintotheblindnutspre-installedinthefuselage.Besuretouse
threadlockonallbolts.

32.Installyourelevatorservosintheprovedlocationandassemblethelinkageasshown
inthefollowingpictures.

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22

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


33.Placetherudderfairingblockintopositionandtracearounditwithafinetippedfelt
marker.Useasharphobbyknifetoremovethecoveringasshownforawoodtowood
bondandglueinplacewithmediumCAorepoxy.Besuretocheckalignmentwith
rudderbeforegluing!

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23

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34.Usingthesamemethodaswiththeaileronsandelevators,gluetherudderhinges
andruddercontrolhornsinplacewith30minuteepoxy.



35.Installtherudderservointhedesignatedlocationinsidetheverticalfinwiththe
outputsplineorientedtowardtherearofthemodelandassemblethelinkageasshown.

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24

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36.Slidethecarbonfiberruddermountingtubeintothereceptacleinthefuselage.Slide
therudderintopositionandsecurewith23mmboltsandwashers.




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25

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37.Installthetailwheelsteeringservointoitsdesignatedlocationandassemblethe
linkageasshown.



38.Ifyouareplanningtoinstallthefloatkitandflyfromwaterinstallthekeelonthe
bottomofthefuselage.Glueinplacewithepoxymakingsureitisperpendiculartothe
bottomofthefuselage.Usetapetokeepitproperlypositioneduntilthegluedries.

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26

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39.Insertthecarbonfibermainwingtubeintothesleeveinthefuselage.Slidethe
wingsintopositiontakingcaretoinserttheservoextensionsintothefuselage.Secure
thewingsbyinsertingthenylonwingboltsintotheholesinthefuselageandthreading
themintotheblindnutinthewingroot.

40.Attachthewingstrutsusingthesupplied3mmcapheadboltsinsertedthroughthe
holesineachendofthestrutsandintotheattachmentpointsinthewingandfuselage.
Youmayfinditeasiesttostartwiththewingattachmentfirst.Don'tfullytightenuntil
bothboltsareinsertedintothepre-installedblindnuts.
Thisconcludestheassemblyprocessforthe120"TurboBushmaster.


Preparingforflight!
Withthewingandstrutsattached,placeyourbatteriesinthemodelandpickupthe
Bushmasterbythewingtube.Shiftthebatteriesuntiltheplanebalancesonthetube,
thensecurethebatterieswithvelcro.Thisisasafelocationtobegintestflying.Itis
recommendyou firstfly themodelinstandardconfiguration togetusedtoitsflight
characteristicsbeforebeginningtoexperimentwithflaps.Whendeployingflapsyou
willneedto addanelevator mixthat compensatesforthe flapsand providesafew
degreesofdownelevator.
ThankssomuchforyourbusinessandwehopeyouenjoyflyingyourTurboBushmaster
asmuchaswehave!

27

