Great Planes GPMA1290 User Manual

Scale: 38% Wingspan: 110.5 in [2805mm] Fuselage Length: 103 in [2595mm] Wing Area: 2279 sq in [147dm2] Weight: 36–38 lb [16330–17235g] Wing Loading: 36–38 oz/sq ft [111–117g/dm2] Engine: 120 – 150cc Spark-Ignition Gas
INSTRUCTION MANUAL
WARRANTY
Great Planes® Model Manufacturing Co. guarantees this kit to
be free from defects in both material and workmanship at the date of purchase. This warranty does not cover any component parts damaged by use or modifi cation. In no case shall Great Planes’ liability exceed the original cost of the purchased kit. Further, Great Planes reserves the right to change or modify this warranty without notice.
In that Great Planes has no control over the fi nal assembly or material used for fi nal assembly, no liability shall be assumed nor accepted for any damage resulting from the use by the user of the fi nal user-assembled product. By the act of using the user­assembled product, the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated with the use of this product, the buyer is advised to return
READ THROUGH THIS MANUAL BEFORE STARTING CONSTRUCTION. IT CONTAINS IMPORTANT
INSTRUCTIONS AND WARNINGS CONCERNING THE ASSEMBLY AND USE OF THIS MODEL.
Entire Contents © Copyright 2007
this kit immediately in new and unused condition to the place of purchase.
To make a warranty claim send the defective part or item to Hobby Services at the address below:
Hobby Services
3002 N. Apollo Dr., Suite 1
Champaign, IL 61822 USA
Include a letter stating your name, return shipping address, as much contact information as possible (daytime telephone number, fax number, e-mail address), a detailed description of the problem and a photocopy of the purchase receipt. Upon receipt of the package, the problem will be evaluated as quickly as possible.
Champaign, Illinois
(217) 398-8970, Ext 5
airsupport@greatplanes.com
GPMZ1290 for GPMA1290 V1.0
TABLE OF CONTENTS
INTRODUCTION
INTRODUCTION ............................................................... 2
SAFETY PRECAUTIONS .................................................3
ITEMS REQUIRED FOR COMPLETION .......................... 3
Engine ........................................................................ 3
Servos ........................................................................ 3
Transmitter and Receiver ........................................... 3
Other Radio Gear ....................................................... 4
Hardware and Accessories ........................................ 4
Covering Tools ........................................................... 4
KIT INSPECTION .............................................................. 4
KIT CONTENTS ................................................................ 5
ORDERING REPLACEMENT PARTS .............................. 5
SHRINK THE COVERING ................................................. 6
ASSEMBLE THE WINGS .................................................. 6
Mount the Aileron Servos ........................................... 6
Hook Up the Ailerons ................................................. 7
ASSEMBLE THE HORIZONTAL STABS ..........................9
ASSEMBLE THE FUSELAGE ..........................................9
Mount the Landing Gear ............................................9
Attach the Rudder .................................................... 11
Install the Rudder Servos ......................................... 12
Hook up the Rudder ................................................. 13
Mount the Engine ..................................................... 14
Hook up the Throttle ................................................. 15
Assemble/Install the Fuel Tank ................................ 15
Finish Radio Installation ........................................... 17
Mount the Cowl ........................................................ 19
GET THE MODEL READY TO FLY ................................. 20
Apply the Decals ...................................................... 20
Set the Control Throws ............................................20
Balance the Model (C.G.).........................................21
Balance the Model Laterally ..................................... 22
PREFLIGHT .................................................................... 22
Identify Your Model ................................................... 22
Ground Check ..........................................................22
Range Check ........................................................... 22
ENGINE SAFETY PRECAUTIONS ................................. 23
AMA SAFETY CODE ...................................................... 23
CHECK LIST ................................................................... 24
FLYING ............................................................................ 24
3D FLYING ...................................................................... 27
Thank you for purchasing the Great Planes 38% Extra 330S ARF. Thousands of R/C modelers have already enjoyed the complete “package” that a Great Planes model delivers— thoroughly illustrated, detailed, complete instruction manuals; rugged, yet lightweight construction; complete hardware packages; and superior fl ight characteristics. But many serious IMAC/Freestyle 3D pilots have not yet been able to enjoy these benefi ts—until now! This Great Planes 38% Extra 330S ARF features all the same, high-quality features of its smaller brothers and sisters. We do realize that most pilots who will be building this model already have experience with high-performance, giant-scale airplanes. But there will still be those who are new to a plane of this size and scope, so for you, none of the details have been omitted. You’ll end up with a model that is complete and properly fi nished, without having to fi gure anything out by yourself.
For the latest technical updates or manual corrections to this model visit the Great Planes web site at www.greatplanes. com. Open the “R/C AIRPLANES” pull down tab across the top of the page, then select “ARFs-GLOW.” Scroll down the page and click on “38% Extra 330S ARF.” If there is new technical information or changes an “Important! TECH NOTICE” box will appear in the upper left corner of the page. Click on the Tech Notice box to read the info.
Note: The stabilizer and wing incidences and engine thrust angles have been factory-built into this model. However, some technically-minded modelers may wish to check these measurements anyway. To view this information visit the web site at www.greatplanes.com and click on “Technical Data.” Due to manufacturing tolerances which will have little or no effect on the way your model will fl y, please expect slight deviations between your model and the published values.
AMA
If you are not already a member of the AMA, please join! The AMA is the governing body of model aviation and membership provides liability insurance coverage, protects modelers’ rights and interests and is required to fl y at most R/C sites.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302
Tele: (800) 435-9262
Fax (765) 741-0057
Or via the Internet at:
IMPORTANT!!! Two of the most important things you can do to preserve the radio controlled aircraft hobby are to avoid fl ying near full-scale aircraft and avoid fl ying near or over groups of people.
2
www.modelaircraft.org
PROTECT YOUR MODEL, YOURSELF
& OTHERS...FOLLOW THESE
IMPORTANT SAFETY PRECAUTIONS
ITEMS REQUIRED FOR COMPLETION
Engine
1. Your 38% Extra 330S ARF should not be considered a toy, but rather a sophisticated, working model that functions very much like a full-size airplane. Because of its performance capabilities, the Extra, if not assembled and operated correctly, could possibly cause injury to yourself or spectators and damage to property.
2. You must assemble the model according to the instructions. Do not alter or modify the model, as doing so may result in an unsafe or unfl yable model. In a few cases the instructions may differ slightly from the photos. In those instances the written instructions should be considered as correct.
3. You must take time to build straight, true and strong.
4. You must use an R/C radio system that is in good condition, a correctly sized engine, and other components as specifi ed in this instruction manual. All components must be correctly installed so that the model operates correctly on the ground and in the air. You must check the operation of the model and all components before every fl ight.
5. If you are not an experienced pilot or have not fl own this type of model before, we recommend that you get the assistance of an experienced pilot in your R/C club for your fi rst fl ights. If you’re not a member of a club, your local hobby shop has information about clubs in your area whose membership includes experienced pilots.
6. While this kit has been fl ight tested to exceed normal use, if the plane will be used for extremely high stress fl ying, such as racing, or if an engine larger than one in the recommended range is used, the modeler is responsible for taking steps to reinforce the high stress points and/or substituting hardware more suitable for the increased stress.
The 38% Extra was designed for a 150cc engine—the Desert Aircraft 150cc in specifi c—but the Extra’s size and weight also make it suitable for any 150cc engine and other engines down to 120cc. Instructions for installation and throttle hookup feature the “DA,” so if using a different engine use the instructions as a guide. The spinner is also drilled to fi t the DA.
Servos
Following are the number of servos required and the minimum torque ratings (at 6 Volts) for each:
(4) Aileron servos with a minimum torque of 190 oz-in
each (such as Futaba® S9155 – FUTM0215)
(3) Rudder servos with a minimum torque of 120 oz-in
each (such as Futaba S9155 – FUTM0215 or Futaba S9350 – FUTM0235)
(2) Elevator servos with a minimum torque of 300 oz-in
each (such as Futaba S9156 – FUTM0216 or Hobbico® CS-170 – HCAM0316) If using Hobbico CS-170 servos,
one (1) servo horn set CS/TS35-59, 63-71 (HCAM1071) must also be purchased separately for each servo.
(1) Ball bearing, "medium-torque” throttle servo (such as
Futaba S9001 – FUTM0075)
Receiver battery with a minimum capacity of 3000 mAh
(such as HydriMax™ Ultra 6.0 Volt 4200mAh NiMH – HCAM6355)
Ignition battery with a minimum capacity of 1000 mAh
(such as HydriMax Ultra 6.0 Volt 2000mAh NiMH – HCAM6351)
7. WARNING: The cowl, wheel pants and landing gear fairings included in this kit are made of fi berglass, the fi bers of which may cause eye, skin and respiratory tract irritation. Never blow into a part (wheel pant, cowl) to remove fi berglass dust, as the dust will blow back into your eyes. Always wear safety goggles, a particle mask and rubber gloves when grinding, drilling and sanding fi berglass parts. Vacuum the parts and the work area thoroughly after working with fi berglass parts.
We, as the kit manufacturer, provide you with a top quality, thoroughly tested kit and instructions, but ultimately the quality and fl yability of your fi nished model depends on how you build it; therefore, we cannot in any way guarantee the performance of your completed model, and no representations are expressed or implied as to the performance or safety of your completed model.
Remember: Take your time and follow the instructions to end up with a well-built model that is straight and true.
Transmitter and Receiver
A minimum of 5 or 6 channels will be required. All three rudder servos may be connected to one channel in the receiver via a servo synchronizer. The aileron servos in one wing should be connected to one channel and the aileron servos in the other wing should be connected to another channel. The two channels for ailerons should be mixed electronically via mixing in the transmitter. The elevator servos may be connected to separate channels in the receiver and mixed electronically through the transmitter, or they can both be connected to a single channel in the receiver. If using one channel for the elevators, a servo reverser will also be required to get one servo to respond in the opposite direction.
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Other Radio Gear
Hardware and Accessories
The following servo extensions were used on the model in the instruction manual:
Note: If using digital servos, be certain to use servo extensions suitable for use with digital servos. The servo extensions listed below are suitable for both analog and digital servos.
(2) 6" [150mm] heavy-duty dual servo extension (coming
from the receiver inside the fuselage for ailerons – FUTM4134 for Futaba)
(2) 6" [150mm] Pro HD servo extensions (1-throttle servo,
1-servo synchronizer for rudder servos – HCAM2701 for Futaba)
(2) 12" [305mm] Pro HD servo extensions (for inboard
aileron servos – HCAM2711 for Futaba)
(2) 36" [915mm] Pro HD servo extensions (for outboard
aileron servos -- HCAM726 for Futaba)
A servo synchronizer for the three rudder servos is also
required (Such as MSA-10 used for Futaba servos – FUTM4155)
If connecting the elevator servos to separate channels in the receiver (and using the mixing in the transmitter) the following servo extensions will also be required:
(2) 6" [150mm] Pro HD servo extensions (HCAM2701
for Futaba)
(2) 12" [305mm] Pro HD servo extensions (HCAM2711
for Futaba)
(2) 36" [915mm] Pro HD servo extensions (HCAM2726
for Futaba)
In addition to typical hobby tools, following is the rest of the hardware and accessories used to fi nish the Extra 330S ARF:
Pro
30-minute epoxy (GPMR6047)
1 oz. [30g] Medium Pro CA+ (GPMR6008) CA applicator tips (HCAR3780) Threadlocker thread locking cement (GPMR6060) (2 pkgs) 3' Du-Bro 1/8" Tygon fuel tubing (DUBQ0493) 1/4" [6.5mm] R/C foam rubber (HCAQ1000) 1/8" single-sided foam tape (GPMQ4424) Silver solder w/fl ux (GPMR8070)
Covering Tools
A Top Flite® or 21st Century® model airplane covering iron with a protective covering sock may be necessary for tightening any covering on the model that may have loosened or formed wrinkles between the time of production and your purchase. The 21st Century iron is preferred as it has a longer cord and a rounded, contoured shoe. A trim iron is not as much of a necessity, but would still be very handy for sealing the edges down inside servo openings and other small areas.
21st Century sealing iron (COVR2700) 21st Century iron cover (COVR2702) 21st Century trim seal iron (COVR2750)
Top Flite MonoKote Top Flite Hot Sock Top Flite MonoKote trim seal iron (TOPR2200)
®
sealing iron (TOPR2100)
iron cover (TOPR2175)
If connecting the elevator servos to the same channel in the receiver, a servo reverser and (2) 36" [915mm] servo extensions will be required:
(1) servo reverser (such as Futaba SR-10 – FUTM4150) (2) 36" [915mm] Pro HD servo extension (HCAM2726 for
Futaba)
These switches and charge receptacles were also used:
(2) Heavy-duty on/off switches (1-ignition battery, 1-
radio system such as Hobbico HD switch for Futaba J (HCAM2761)
(2) Ernst Charge Receptacles (ERNM3001 for Futaba)
KIT INSPECTION
Before starting to build, inspect the parts to make sure they are of acceptable quality. If any parts are missing or are not of acceptable quality, or if you need assistance with assembly, contact Product Support. When reporting defective or missing parts, use the part names exactly as they are written in the Kit Contents list.
Great Planes Product Support
3002 N. Apollo Drive, Suite 1
Champaign, IL 61822
Telephone: (217) 398-8970, ext. 5
Fax: (217) 398-7721
E-mail: airsupport@greatplanes.com
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KIT CONTENTS
1
8
6
9
5
1. Fuselage
2. Wing w/Ailerons
3. Stabilizer w/Elevators
4. Rudder
5. Wheel Pants
10
7
6. Landing Gear
7. Wheels
8. Spinner
9. Fuel Tank
10. Landing Gear Fairings
ORDERING REPLACEMENT PARTS
Replacement parts for the Great Planes 38% Extra 330S ARF are available using the order numbers in the Replacement Parts List that follows. The fastest, most economical service can be provided by your hobby dealer or mail-order company.
To locate a hobby dealer, visit the Great Planes web site at www. greatplanes.com. Choose “Where to Buy” at the bottom of the menu on the left side of the page. Follow the instructions provided on the page to locate a U.S., Canadian or International dealer.
Parts may also be ordered directly from Hobby Services by calling (217) 398-0007, or via facsimile at (217) 398-7721, but full retail prices and shipping and handling charges will apply. Illinois and Nevada residents will also be charged sales tax. If ordering via fax, include a Visa® or MasterCard® number and expiration date for payment.
Mail parts orders and payments by personal check to:
Hobby Services
3002 N. Apollo Drive, Suite 1
Champaign, IL 61822
Be certain to specify the order number exactly as listed in the Replacement Parts List. Payment by credit card or personal check only; no C.O.D.
If additional assistance is required for any reason, contact Product Support by telephone at (217) 398-8970, or by e-mail at productsupport@greatplanes.com.
3
12
13
11
2
4
11. Wing Tube
12. Stab Tubes
13. Tail Gear
Replacement Parts List Order Number Description How to Purchase
Missing pieces ...........Contact Product Support
Instruction manual .....Contact Product Support
Full-size plans ............................... Not available
Contact your hobby supplier for the following parts:
GPMA3190 ......... Wing Set
GPMA3191 ......... Fuselage w/Canopy
GPMA3192 ......... Horizontal Stabilizer
GPMA3193 ......... Rudder
GPMA3194 ......... Hatch w/Canopy
GPMA3195 ......... Cowl
GPMA3196 ......... Wheelpants
GPMA3197 ......... Carbon Fiber Landing Gear
GPMA3198 ......... Wing Tube
GPMA3199 ......... Stab Joiners
GPMA3200 ......... Spinner
GPMA3201 ......... Canopy Only
GPMA3202 ......... Tail Gear Set
GPMQ3728 ......... Deluxe 6-32 Pull-Pull Set
GPMA3203 ......... 8-32 Rudder Torque Rod Mount
GPMM1107 ........ Single-Sided 1.5" Servo Arm Set
GPMM1167 ........ Double-Sided 3" Servo Arm Set
GPMA3204 ......... Rudder Servo Tray
GPMQ3760 ......... Turnbuckle Pushrod 3.5" x 6-32
GPMQ3754 ......... Turnbuckle Pushrod 2.125" x 6-32
GPMA3206 ......... Decals
GPMA3207 ......... Pilot
5
5
SHRINK THE COVERING
p
2. Also cut the covering from the holes in the top and
bottom of the ailerons for the threaded torque rods.
Torque Rod Nut
Torque Rod Washer
Torque Rod Washer
1. Where necessary, use a covering iron (set to
approximately 250°F [120°C] with a covering sock to go over any parts of the model where the covering requires tightening. Over sheeted areas, press down on the iron to bond the covering to the wood. If the covering expands or bubbles, use less heat. Note: Naptha (lighter fl uid) can be used to remove any adhesive left from the masking tape that may have been used to hold any of the parts together.
2. Make sure the elevators and ailerons are securely
hinged by pulling hard on each control surface.
ASSEMBLE THE WINGS
Mount the Aileron Servos
Servo opening in wing.
Cut the covering 1/8" [3mm] inside the edges of the opening. Slit the covering u to the corners.
[75mm]
(Ailerons and Elevators)
75mm Threaded Torque Rod
3"
3. Use a cordless drill with a Phillips bit and a 5/16" [or
8mm] wrench or pliers to hold the plastic torque rod nut and mount two 3" [75mm] threaded torque rods into each aileron with a torque rod washer on both sides.
1. Cut the covering 1/8" [3mm] inside the edges of both
aileron servo openings in the bottom of both wings. Slit the covering up to the corners and use a trim iron to seal the covering down inside.
4. Use epoxy to glue two 10 x 30mm hardwood wing
dowels into the root end of each wing.
666
Hook Up the Ailerons
5. Connect a 12" [305mm] servo extension (HCAM2711
for Futaba) to one of the aileron servos and 36" [915mm] servo extension (HCAM2726 for Futaba) to the other aileron servo. Secure each connection with 1-1/2" [38mm] pieces of heat shrink tubing cut from one of the 3" [75mm] pieces included with this kit.
Use 7/64" [2.8mm]
(or 1/8" [3.2mm]) drill
Enlarge the
holes indicated
Futaba Servo Wheel
Drill holes in
the mold marks.
Bottom of Hobbico
Servo Wheel
1. If using Futaba servos, drill out the holes in the servo
wheel with a 7/64" [2.8mm] (or 1/8" [3.2mm]) drill. If using different servos, use one of the aluminum servo arms that came with this kit as a template for drilling the holes. All the servo wheels used for the control surfaces in this model require drilling, so if you have all your servo wheels handy you could drill them all now, or just drill them as needed.
Note: The servo wheels that come with the CS/TS35-59, 63­71 Hobbico Servo Horn set (HCAM1071) have mold marks in the bottom that happen to align with the holes in the aluminum servo arms. Double-check to make sure the mold marks align with the holes in one of the servo arms. Then, drill 1/16" [1.6mm] pilot holes at the marks. Enlarge the pilot holes with a 7/64" [2.8mm] (or 1/8" [3.2mm]) drill.
6. Tie the string in one of the wings to the servo wires as
shown. Then, pull them through the tube in the wing.
7. Place the aileron servos in the servo openings of one
of the wings. Drill 1/16" [1.6mm] holes for the servo mounting screws. Temporarily mount the servos with the screws that came with them. Note: For some JR (or other brand) servos, the servo mounts may require slight trimming to accommodate the servos and larger holes may have to be drilled for larger servo mounting screws.
8. IMPORTANT: Remove the servo mounting screws
and set the servos aside (without pulling the servo leads out of the wing). Add a few drops of thin CA to each screw hole to harden the “threads.” Allow the CA to harden. Then, remount the servos.
Whenever screws are mounted into wood you must harden the holes with CA after installing, and then removing the screws. The complete process will not be written out every time this is necessary. Instead, you will simply be reminded to “harden the screw holes with thin CA.”
9. Mount the aileron servos in the other wing the same
way—don’t forget to harden the screw holes with thin CA!
Your radio system will be required for the next step, so gather your transmitter, receiver, battery and on/off switch.
2. Connect one of the aileron servos to your receiver and
turn the system on. Center the trim and position the servo wheel on the servo so that when the top servo arm will be mounted to the wheel it will be perpendicular to the servo.
7
Scratch a small arrow
h
onto the servo wheel so you will know whic way is forward.
3. Once the correct orientation of the servo wheel has
been determined, use a hobby knife to scratch an arrow on the wheel so you will know how to mount the arm later.
Threaded Retainer Disc
Lock Pin
Pin Clevis
Single-Sided
Top Servo Arm
3mm Spacer
Servo Wheel
Single-Sided
Bottom Servo Arm
4-40 x 7/16" [10mm]
Flat-Head Phillips Screws
(USE THREADLOCKER)
4-40 Nut
1mm Standoff
Ball Link Ball
1mm Standoff
Servo Arm Assembly
4. Assemble one of the servo arm assemblies with the
parts shown—it’s easiest to fi rst mount the ball link and 1mm standoffs to the servo arms and temporarily secure with the 4-40 nut, then join the servo wheel and spacer.
IMPORTANT: Threadlocker must be used on the threads of all fi ve screws.
6. Thread one of the reverse-thread pin clevises onto
the reverse-threaded end of a 2-1/2" [64mm] turnbuckle pushrod. Thread the turnbuckle pushrod to the ball link on the servo arm and connect the pin clevis to the torque rod horn with the lock pin.
7. Turn on your radio and adjust the turnbuckle pushrod
so the aileron will be neutral when the servo is centered. The turnbuckle should be threaded equally into both the ball link and the pin clevis.
8. Connect the outboard aileron to your receiver. With the
radio on, connect the outboard servo to the outboard torque rod arm using the same hardware as the inboard servo.
Adjust the torque rod horns up or
down to equalize the pressure from
the pushrods when the servos are
at the extremes of their throw.
Pin Clevis
2-1/2" [64mm]
Turnbuckle Pushrod
5. Gather all the pin clevises included with this kit. Note
that only two have a “normal” thread and the rest have a reverse thread. Test-thread each pin clevis onto the “normal” threaded end of one of the 2-1/2" [64mm] turnbuckle pushrods until you fi nd the two that fi t. Mark those as “N” and set them aside.
9. With the radio on and both servos still connected to the
receiver, adjust the position of the torque rod horns on the torque rods so the servos will not be “fi ghting” each other and will be applying the same pressure on the horns when the servos are at the extremes of their throw.
10. Hook up the aileron on the other wing the same way.
8
Cotter Pin
Pin Washer
11. While you have your wings on your workbench and
the servos operating, you could go ahead and set the control throws as indicated on page 21 now, or wait until the model has been completed. Once the aileron throws have been set, fasten the lock pins to the clevises and control horns with a pin washer followed by a cotter pin. Bend the cotter pins over so they won’t come out. Secure all the servo wheels to the servos with the screws that came with them. Note: If your servos have metal output shafts, use threadlocker on the threads of the servo arm screws.
except the turnbuckle pushrods are 3-1/2" [90mm] in length. Also remember to harden the screw holes for the servo mounting screws.
3. Wet the mounting tabs on the ends of both stab halves
with thin CA. Allow the CA to penetrate into the wood and harden.
4. When ready to set the throws or check the C.G. and
you need to mount the stab halves to the fuselage, use the carbon fi ber stabilizer tubes and two 4-40 x 1/2" [13mm] SHCS, #4 lock washers and #4 fl at washers in each stab. When mounting the stabs for fl ying, use threadlocker on the threads of the screws.
12. Use CA or rubber cement to glue the black, foam
rubber strips to the end of both wings.
ASSEMBLE THE HORIZONTAL STABS
1. Install a 3" [75mm] torque rod in both elevators with
the torque rod washers and torque rod nuts. Also cut the covering from the elevator servo openings in the horizontal stabilizers (stabs).
2. Mount the elevator servos and hook up the elevators—
all the hardware is the same as was used for the ailerons
ASSEMBLE THE FUSELAGE
Mount the Landing Gear
First the tail gear…
1. Temporarily remove the tail wheel bracket from the tail
gear wire with a 1.5mm Allen wrench. File a fl at spot in the wire for the set screw in the bottom collar. Reassemble the tail gear with a drop of threadlocker on the threads of the set screws.
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