Hangar 9 Extra 260 Assembly Manual

35% Extra 260

Assembly mAnuAl

Specifications

Wingspan ......................................105 in (2667mm)

Overall Length ............ 98 in (2489mm) with spinner

Wing Area ...........................2003 sq in (129 sq dm)

Flying Weight .......................... 27–30 lb (12–14 kg)

Engine Size ......................................100–116cc gas

Radio........................................... 4-channel or more

Servos .........................................................8 servos

(9 if using two rudder servos instead of 1)

Spinner Size .............................................. 4

Hardware Included ..............................................Yes

1

/2-inch

Table of Contents

Using the Manual ..................................................................3

Required Tools and Adhesives ........................................................3

UltraCote Covering Colors ...........................................................3

Before Starting Assembly ............................................................3

Radio and Power Systems Requirements ................................................4

Recommended JR, JR

Recommended Engine Setup .........................................................4

FS One ..........................................................................4

Warranty Period ...................................................................5

Limited Warranty...................................................................5

Damage Limits ....................................................................5

Safety Precautions .................................................................5

Questions, Assistance, and Repairs ....................................................6

Inspection or Repairs ...............................................................6

Warranty Inspection and Repairs.......................................................6

Non-Warranty Repairs...............................................................6

SPORT and Spektrum Systems ......................................4

Safety, Precautions, and Warnings .....................................................7

Contents of Kit ....................................................................7

Aileron Servo Installation ............................................................8

Elevator Servo Installation ..........................................................12

Rudder and Rudder Servo Installation..................................................13

Landing Gear Installation ...........................................................16

Stabilizer Installation...............................................................19

Engine Installation (DA100) .........................................................21

Engine Installation (Evolution 116GX) .................................................26

Receiver Installation ...............................................................30

Pilot and Canopy Installation ........................................................32

Radio Setup .....................................................................33

Control Throws ...................................................................34

Computer Radio Enhancements ......................................................34

Recommended Center of Gravity (CG) .................................................35

Rates and Expos ..................................................................35

Preflight ........................................................................36

Range Test Your Radio .............................................................37

Instructions for Disposal of WEEE by Users in the European Union...........................37

2007 Official AMA National Model Aircraft Safety Code ................................ 38–39

2

Using the Manual

This manual is divided into sections to help make assembly easier to understand, and to provide breaks between each
major section. In addition, check boxes have been placed next to each step to keep track of each step completed. Steps
with a single box (
repeating, such as for a right or left wing panel, two servos, etc. Remember to take your time and follow the directions.

) are performed once, while steps with two boxes ( ) indicate that the step will require

Required Tools and Adhesives

Tools

• Rotary tool (Dremel) • Hobby scissors

• Pliers • Clamp

• T-pins • Crimping tool/vice grips

• Solder • String

• Solder gun • 1/4-inch (6mm) foam

• Tape • Hobby knife

• Phillips screwdriver • Drill

• Felt-tipped pen • Nut driver: 1/4-inch

• Hex wrench: 5/64-inch, 3/32-inch, 7/64-inch, 1/8-inch • Angle Pro Incidence Meter (HAN192)

• Drill bit: 1/16-inch (1.5mm), 5/64-inch (2mm), 5/32-inch (4mm), 3/16-inch (4.5mm)

Adhesives

• Thin CA (PAAPT08) • Medium CA (PAAPT02)

• 30-Minute Epoxy (HAN8002) • Formula 560 Canopy Glue (PAAPT56)

• CA Remover/Debonder (PAAPT16) • Pacer Z-42 Threadlock (PAAPT42)

UltraCote Covering Colors

• White (HANU870) • Cub Yellow (HANU884)

• True Red (HANU866) • Pearl Purple (HANU847)

Before Starting Assembly

Before beginning the assembly of the 35% Extra 260, remove each part from its bag for inspection. Closely inspect
the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact the
place of purchase.

If you find any wrinkles in the covering, use a heat gun or sealing iron to remove them. Use caution while working around
areas where the colors overlap to prevent separating the colors.

HAN101 – Sealing Iron

HAN100 – Heat Gun

HAN141 – Sealing Iron

Sock

HAN150 – Covering Glove

3

Radio and Power Systems Requirements

• 7-channel computer radio system (minimum) w/receiver • Large Servo Arms (JRPA236) (8 pkgs)

• 24-Inch Servo Lead Extension (JRPA102) (5) • JR Charge Jack Switch (JRPA004) (3)

• 36-inch Servo Lead Extension (JRPA103) (3) • Choke Ring (JRPA029) (For throttle servo lead)

• JR 8611A or 8711 Metal Geared high torque servos (7) or equivalent
Caution: Only metal-geared servos of 180 oz in torque or greater should be used on the control surfaces.

• 2700mAh or larger for receiver (2) (A minimum of 3000mAh is required when using super high-torque servos)

• 1500mAh or larger for ignition (4.8 or 6.0V for DA-100, 3-cell Li-Po for Evolution

The elevator installation will require:

Two servos and mixing through the radio

Or

Two servos and a JR® MatchBox™ (JPA0900)

®

116cc))

Recommended JR, JR SPORT and Spektrum Systems

• JR 10X

• JR XP9303

• JR X9303 2.4

• JR XP7202

• Spektrum DX-7

JR XP9303

Spektrum DX7

JR 10X

Recommended Engine Setup

DA-100

• In cowl mufflers

or

• MTW 75 canisters with headers

• 27 x 10 propeller

Evolution 116

• In cowl mufflers

or

• MTW 75 canisters with headers

• 28 x 10 propeller

FS One

With FS One® you get more than photorealistic fields, gorgeous
skies and realistic-looking aircraft. You get incredibly advanced
aerodynamic modeling that simulates every possible aspect
of real-world flight.

4

HANS2000

Warranty Period

Exclusive Warranty- Horizon Hobby, Inc., (Horizon) warranties that the Products purchased (the "Product") will be free
from defects in materials and workmanship at the date of purchase by the Purchaser.

Limited Warranty

(a) This warranty is limited to the original Purchaser ("Purchaser") and is not transferable. REPAIR OR REPLACEMENT

AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE PURCHASER. This warranty covers only

those Products purchased from an authorized Horizon dealer. Third party transactions are not covered by this warranty.
Proof of purchase is required for warranty claims. Further, Horizon reserves the right to change or modify this warranty
without notice and disclaims all other warranties, express or implied.

(b) Limitations- HORIZON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON-

INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCT. THE

PURCHASER ACKNOWLEDGES THAT THEY ALONE HAVE DETERMINED THAT THE PRODUCT WILL SUITABLY MEET

THE REQUIREMENTS OF THE PURCHASER’S INTENDED USE.
(c) Purchaser Remedy- Horizon's sole obligation hereunder shall be that Horizon will, at its option, (i) repair or (ii)

replace, any Product determined by Horizon to be defective. In the event of a defect, these are the Purchaser's exclusive
remedies. Horizon reserves the right to inspect any and all equipment involved in a warranty claim. Repair or replacement
decisions are at the sole discretion of Horizon. This warranty does not cover cosmetic damage or damage due to acts of
God, accident, misuse, abuse, negligence, commercial use, or modification of or to any part of the Product. This warranty
does not cover damage due to improper installation, operation, maintenance, or attempted repair by anyone other than
Horizon. Return of any goods by Purchaser must be approved in writing by Horizon before shipment.

Damage Limits

HORIZON SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR

PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCT, WHETHER SUCH CLAIM
IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. Further, in no event shall the liability of
Horizon exceed the individual price of the Product on which liability is asserted. As Horizon has no control over use,
setup, final assembly, modification or misuse, no liability shall be assumed nor accepted for any resulting damage or
injury. By the act of use, setup or assembly, the user accepts all resulting liability.

If you as the Purchaser or user are not prepared to accept the liability associated with the use of this Product, you are
advised to return this Product immediately in new and unused condition to the place of purchase.

Law: These Terms are governed by Illinois law (without regard to conflict of law principals).

Safety Precautions

This is a sophisticated hobby Product and not a toy. It must be operated with caution and common sense and requires
some basic mechanical ability. Failure to operate this Product in a safe and responsible manner could result in injury
or damage to the Product or other property. This Product is not intended for use by children without direct adult
supervision. The Product manual contains instructions for safety, operation and maintenance. It is essential to read
and follow all the instructions and warnings in the manual, prior to assembly, setup or use, in order to operate correctly
and avoid damage or injury.

5

Questions, Assistance, and Repairs

Your local hobby store and/or place of purchase cannot provide warranty support or repair. Once assembly, setup or
use of the Product has been started, you must contact Horizon directly. This will enable Horizon to better answer your
questions and service you in the event that you may need any assistance. For questions or assistance, please direct your
email to [e-mail], or call 877.504.0233 toll free to speak to a service technician.

Inspection or Repairs

If this Product needs to be inspected or repaired, please call for a Return Merchandise Authorization (RMA). Pack
the Product securely using a shipping carton. Please note that original boxes may be included, but are not designed
to withstand the rigors of shipping without additional protection. Ship via a carrier that provides tracking and insurance
for lost or damaged parcels, as Horizon is not responsible for merchandise until it arrives and is accepted
at our facility. A Service Repair Request is available at www.horizonhobby.com on the “Support” tab. If you do not
have internet access, please include a letter with your complete name, street address, email address and phone number
where you can be reached during business days, your RMA number, a list of the included items, method of payment
for any non-warranty expenses and a brief summary of the problem. Your original sales receipt must also be included
for warranty consideration. Be sure your name, address, and RMA number are clearly written on the outside of the
shipping carton.

Warranty Inspection and Repairs

To receive warranty service, you must include your original sales receipt verifying the proof-of-purchase
date. Provided warranty conditions have been met, your Product will be repaired or replaced free of charge. Repair or
replacement decisions are at the sole discretion of Horizon Hobby.

Non-Warranty Repairs

Should your repair not be covered by warranty the repair will be completed and payment will be
required without notification or estimate of the expense unless the expense exceeds 50% of the retail
purchase cost. By submitting the item for repair you are agreeing to payment of the repair without notification. Repair

estimates are available upon request. You must include this request with your repair. Non-warranty repair estimates will
be billed a minimum of ½ hour of labor. In addition you will be billed for return freight. Please advise us of your preferred

method of payment. Horizon accepts money orders and cashiers checks, as well as Visa, MasterCard, American Express,

and Discover cards. If you choose to pay by credit card, please include your credit card number and expiration date. Any
repair left unpaid or unclaimed after 90 days will be considered abandoned and will be disposed of accordingly. Please
note: non-warranty repair is only available on electronics and model engines.

Electronics and engines requiring inspection or repair should be shipped to the following address:

Horizon Service Center

4105 Fieldstone Road

Champaign, Illinois 61822

All other Products requiring warranty inspection or repair should be shipped to the following address:

Please call 877-504-0233 with any questions or concerns regarding this product or warranty.

6

Horizon Product Support

4105 Fieldstone Road

Champaign, Illinois 61822

Safety, Precautions, and Warnings

This model is controlled by a radio signal that is subject to interference from many sources outside your control. This
interference can cause momentary loss of control so it is advisable to always keep a safe distance in all directions around
your model, as this margin will help to avoid collisions or injury.

• Always operate your model in an open area away from cars, traffic, or people.

• Avoid operating your model in the street where injury or damage can occur.

• Never operate the model into the street or populated areas for any reason.

• Never operate your model with low transmitter batteries.

• Carefully follow the directions and warnings for this and any optional support equipment (chargers, rechargeable

battery packs, etc.) that you use.

• Keep all chemicals, small parts and anything electrical out of the reach of children.

• Moisture causes damage to electronics. Avoid water exposure to all equipment not specifically designed and protected

for this purpose.

Contents of Kit

Replacement Parts

A. HAN1001 Fuselage w/Hatch
B. HAN1002 Right Wing Panel w/Aileron
C. HAN1003 Left Wing Panel w/Aileron
D. HAN1004 Right Stabilizer w/Elevator
E. HAN1005 Left Stabilizer w/Elevator
F. HAN1006 Anodized Wing Tube
G. HAN1007 Anodized Stabilizer Tube
H. HAN1008 Rudder
I. HAN1009 Canopy

J. HAN1010 Canopy Hatch
K. HAN1011 Fiberglass Painted Cowl
L. HAN1012 Landing Gear
M. HAN1014 Painted Wheel Pants
N. HAN331 Tailwheel Assembly
O. HAN1015 Hardware Kit
P. HAN360 Painted Pilot Helmet

Not Shown

HAN1013 Decal Set

J

K

B

I

A

H

D

E

C

G

O

M

P

N

F

L

7

Aileron Servo Installation

Required Parts

• Wing panel (left and right)

• Ball end w/hardware (4) • Control horn (4)

• 3-inch (76mm) linkage (4)

Required Tools and Adhesives

®

• JR

MatchBox™ (2) • Phillips screwdriver

• Ruler • Nut driver: 1/4-inch

• Hex wrench: 3/32-inch • String w/weight

• Servo extension, 24-inch (610mm) (2)

1

• 1

/2-inch Single Side Alum Adj.

Spline Servo Arm (4)

  Step 1

Secure a 24-inch (610mm) servo extension to the
outboard aileron servo.

  Step 3

Tip the wing so the root is facing down and lower the
weight through the wing.

  Step 4

Tie the string to the servo extension.

  Step 2

Tie a weight to a piece of string. Lower the weight into the
opening for the outboard aileron servo.

8

  Step 5

  Step 7

Use the string to pull the extension through the wing. Tape
the extension so it will not fall back into the wing.

  Step 6

Secure the servo using the hardware provided with the
servo. The output of the servo faces the trailing edge.

Thread the control horn onto the control horn screw so the
bottom of the horn is 1 inch (25mm) from the surface of
the aileron.

  Step 8

Install the inboard aileron servo and the control horn.
Thread the control horn so it is 13/16-inch (21mm) from
the aileron surface as shown.

  Step 9

Plug both aileron servos into the receiver. Center the
aileron trim and stick to center the aileron servos. Also
make sure any sub-trims have been set to zero in the radio
memory. Check the operation of the servos at this time.

9

  Step 10

  Step 12

Attach the ball end to the bottom side of the servo
arm using the ball end hardware. The hole used will be

1

1

/4-inch (32mm) from the center of the servo arm.

  Step 11

With the servo at the neutral position and radio on, attach
the servo arm to the servo. Place it on the spline that sets
the arm closest to parallel with the hinge line. (This will
be fine tuned later.) Turn off the receiver and manually turn
the arm so it is parallel with the hinge line.

Assemble and install the 3-inch (76mm) linkage for the
outboard aileron servo ONLY at this time. Adjust the
linkage to center the aileron and attach the linkage to the
horn with the setscrew. Remember to keep the servo arm
parallel to the hinge line while adjusting the linkage.

  Step 13

Plug the aileron servos into a JR MatchBox
servo plugs into Port 1 and the inboard servo plugs into
Port 2. The MatchBox is used to link the two servos to
operate properly. Plug the MatchBox into the aileron
channel of your receiver.

.

The outboard

10

  Step 14

With only the outboard aileron linkage attached to the
control horn, turn on the radio and adjust the sub-trim in
the transmitter until the aileron is at the neutral position.
Deflect the stick to full right aileron and adjust the travel
adjust so the deflection is 34.4 degrees. Repeat this for
full left deflection and adjust for 33 degrees.

  Step 15

  Step 18

Turn the dial on the MatchBox to position 2.

  Step 16

Use the MatchBox to adjust the center position of the
inboard servo, aligning the servo arm parallel to the hinge
line. Assemble and install the 3-inch (76mm) linkage
for the outboard aileron servo, but do not attach it to the
control horn at this time. Confirm that the hole in the ball
end is perfectly aligned with the hole in the control horn.

Repeat for full left aileron.

  Step 19

BEFORE turning off the power to the receiver, turn the dial
on the MatchBox back to the 0 position to save the data.

  Step 20

  Step 17

Deflect the aileron stick to full right and check the
alignment of the hole in the ball end with the hole in the
control horn. If they are misaligned (likely), adjust the
travel of the servo with the MatchBox while holding full
right stick, until the holes align perfectly.

Recheck to be sure the neutral and full deflection in
each direction are correct and the holes are aligned in
all 3 positions BEFORE securing the ball end to the
control horn.

  Step 21

Install the screw to secure the ball end to the control horn.

 Step 22

Repeat steps 1 through 21 for the remaining wing panel,
only plug the matchbox into the auxiliary channel that is
being mixed to the aileron channel for this wing panel.

11

Elevator Servo Installation

Required Parts

• Ball end w/hardware (2) • Control horn (2)

• Stabilizer/elevator (left and right)

• 3-inch (76mm) linkage (2)

Required Tools and Adhesives

• Hex wrench: 3/32-inch

• Nut driver: 1/4-inch

1

• 1

/2-inch Single Side Alum Adj. Spline Servo Arm

(2)

  Step 1

Install the elevator servo into the stabilizer. Make sure to
pull the servo lead through the opening toward the leading
edge before placing the servo.

  Step 3

Assemble the linkage for the elevator using a ball end,
control horn and a 3-inch (76mm) linkage. Thread the
horn onto the screw so the bottom of the horn is 3/4-inch
(19mm) from the surface of the elevator.

  Step 4

  Step 2

Install the servo arm onto the elevator servo. Use the radio
system to center the servo beforehand.

Attach the ball end to the servo horn using the hardware
provided with the ball end. The attachment point will be

1

1

/2-inch (38mm) from the center of the servo horn.

 Step 5

Repeat Steps 1 through 4 for the remaining elevator servo
and linkage.

12

Rudder and Rudder Servo Installation

Required Parts

• Ball end w/hardware (2) • Control horn (2)

• Rudder • Fuselage

• Removable hinge pin • Tiller arm

• Tail gear assembly • Steering spring (2)

• #6 x 5/8-inch socket head sheet metal screws (4)

1

• 4

/2-inch (114mm) linkage

Required Tools and Adhesives

• Thin CA • Drill

• Drill bit: 3/32-inch (2.5mm)

• Hex wrench: 3/32-inch

• Nut driver: 1/4-inch

1

• 1

/2-inch Single Side Alum Adj. Spline Servo Arm

Note: When using a servo with less than
300 oz/in of torque, it is highly recommended
to use two rudder servos and link them
together using a JR MatchBox. An additional
servo location on the opposite side of the
fuselage will require the removal of the
covering to install your second servo.

 Step 2

Assemble the rudder linkage using a 4
linkage, ball end and control horn. The control horn is
then threaded on the control horn screw so the bottom of
the horn is 5/8-inch (16mm) from the control surface.

1

/2-inch (114mm)

 Step 3

Attach the rudder to the fin/fuselage using the hinge pin
located in the hinges.

 Step 1

Secure a 24-inch (610mm) servo extension to the rudder
servo. Mount the servo in the fuselage as shown.

Hint: Use a drill to aid in installing

the hinge wire. This will help guide the
wire through each of the hinges.

13

 Step 4

 Step 6

Attach the ball end to the servo horn using the hardware
provided with the ball end. The attachment point will be

1

1

/2-inch (38mm) from the center of the servo horn.

 Step 5

Position the tail gear assembly on the bottom of the
fuselage. Use a felt-tipped pen to mark the locations for
the two screws.

Drill each of the locations using a drill and 3/32-inch
(2.5mm) drill bit.

 Step 7

Thread a #6 x 5/8-inch socket head sheet metal screw into

the holes, then remove the screw.

Note: The tail gear will keep the rudder

hinge in position. You will need to trim the
removable hinge pin so it is 1/4-inch (4mm)
above the tail gear when it has been installed.

14

 Step 8

 Step 10

Apply a few drops of thin CA into each of the two holes to
harden the wood. This will help in preventing the screws
from vibrating loose.

 Step 9

Follow Steps 5 through 8 to attach the tiller arm to the

bottom of the rudder with two #6 x 5/8-inch socket head

sheet metal screws.

Attach the tail gear assembly to the bottom of the fuselage

using two #6 x 5/8-inch socket head sheet metal screws.

 Step 11

Complete the rudder installation by connecting the tail
wheel to the tiller arm with two steering springs.

15

Landing Gear Installation

Required Parts

• Fuselage assembly • Main landing gear

• #8 washer (4) • 8-32 locknut (4)

• Axle w/nut (2) • #4 washer (4)

• 4-40 blind nut (4)

1

• 4

/2-inch (114mm) wheel (2)

• 4-40 x 1/2-inch socket head screw (4)

• 5/32-inch wheel collar w/setscrews (4)

Required Tools and Adhesives

• Threadlock • Drill

• Drill bit: 9/64-inch (3.5mm)

• Hex wrench: .050-inch, 3/32-inch

 Step 1

Attach the landing gear to the fuselage using four
8-32 x 3/4-inch socket head screws, four #8 washers
and four 8-32 lock nuts.

 Step 2

Secure the axle to the main landing gear.

 Step 3

Use a file to create a flat on the axle for the setscrews in
the collars to tighten onto. This will help in preventing
them from loosening in flight.

16

 Step 3

 Step 5

Attach the wheel to the axle using two 5/32-inch wheel
collars. The collars are placed on either side of the wheel.

Note: Always use threadlock on

metal-to-metal fasteners to prevent
them from vibrating loose.

Mark the location for the two screws through the landing
gear and onto the wheel pant using a felt-tipped pen.

 Step 6

Drill the locations marked in the previous step using a
drill and 9/64-inch (3.5mm) drill bit.

 Step 4

Place the fuselage on a level surface. Slide the wheel pant
into position. The pant must be positioned so it will not
come in contact with the surface.

17

 Step 7

 Step 8

Use pliers to install the two 4-40 blind nuts in the wheel
pant as shown.

Secure the wheel pant to the landing gear using two

4-40 x 1/2-inch socket head screws and two #4 washers.

Note: Always use threadlock on

metal-to-metal fasteners to prevent
them from vibrating loose.

18

Stabilizer Installation

Required Parts

• Fuselage assembly • Stabilizer/elevator (2)

• Stabilizer tube • #4 washer (4)

• 4-40 x 1/2-inch socket head screw(4)

Required Tools and Adhesives

• Threadlock • Hobby knife

• Hex wrench: 3/32-inch • Tap handle

• 4-40 tap • Drill

• Drill bit: 1/16-inch (1.5mm), 1/8-inch (3mm)

 Step 1

Slide the stabilizer tube into one of the stabilizer halves.

  Step 3

Secure a 24-inch (610mm) servo extension to the elevator
servo lead. Pass the extension into the fuselage, then slide
the tube into the fuselage.

  Step 4

Use a 4-40 x 1/2-inch socket head screw and #4 washer

to secure the position of the stabilizer.

  Step 2

Use a hobby knife to remove the covering from the
opening in the fuselage for the servo lead.

Note: Always use threadlock on

metal-to-metal fasteners to prevent
them from vibrating loose.

 Step 5

Repeat Steps 2 through 4 for the remaining stabilizer.

19

 Step 6

 Step 8

Drill a pilot hole in the stabilizer tube using a drill and
1/16-inch (1.5mm) drill bit.

 Step 7

Remove the stabilizer tube and use a drill and 1/8-inch
(3mm) drill bit to drill a hole in the stabilizer tube.

Secure the position of the tube using a 4-40 x 1/2-inch

socket head screw and #4 washer. The screw will thread

into a blind nut that is installed inside the stabilizer.

 Step 9

Repeat Steps 6 through 8 for the remaining stab
tube screw.

20

Engine Installation (DA100)

Required Parts

• Fuselage assembly

Required Tools and Adhesives

• Threadlock

Note: For simplicity the DA will be shown

with canister installation and the Evolution
with Muffler installation. Either engine
can be used with either exhaust option.

 Step 1

Collect the items shown for the installation of your
particular engine.

 Step 3

Use a drill and 5/16-inch (8mm) drill bit to drill the holes
in the firewall for mounting the engine.

 Step 4

Install the 1/4-20 blind nuts from the back side of the
firewall. You can use the bolts and standoffs to pull the
blind nuts into position.

 Step 2

Measure mark and drill firewall to correct dimensions and
offset to the left side.

 Step 5

Install engine using four 2
aluminum standoffs and four 1/4-20 x 3
head bolts and four 1/4-inch lock washers.

7

/8-inch (73mm) machined

3

/4-inch socket

21

 Step 6

 Step 7

Use a hobby knife to trim the covering from the opening
on the bottom of the fuselage. Leave enough material
that you can use the covering to seal the opening with a
covering iron.

Install silicone tubes (8 total) in each of the two canister
mounts.

22

 Step 8

 Step 9

Install throttle servo and attach the linkage (supplied) with
a 4-40 ball link on each end.

Slide the canister mufflers into model and attach the
headers to the engine.

23

 Step 10

 Step 11

Secure the ignition module to the engine box. Make
the connections between the ignition box and engine
at this time.

Install the switch for the ignition at the front of the
fuselage as shown.

 Step 12

Secure the battery for the ignition inside the fuselage
using a hook and loop strap. Make sure to add a few
pieces of foam between the fuselage and battery to prevent
damage to the battery caused by vibration. Connect the
battery to the ignition switch.

24

 Step 13

Attach the fuel line from the fuel tank to the carburetor.
Mak sure the line is from the clunk and not the vent line.

 Step 14

 Step 17

Cut the line between the carburetor and fuel tank to install
a Fuel Dot (HAN115). This will make fueling the tank
much easier when the cowl is installed.

 Step 15

Route the vent line from the fuel tank out the bottom
of the cowl.

Make a circular opening under the carb in the cowling so
the choke butterfly can be manually operated.

 Step 16

Make any necessary cutouts to clear the engine
components in the cowl. Remove a section from the
bottom of the cowling near the mufflers for cooling
outlet as shown. This opening is necessary to allow
cooling air to pass through the cowling to prevent
overheating of your engine.

25

Engine Installation (Evolution 116GX)

Required Parts

• Fuselage assembly

Required Tools and Adhesives

• Threadlock

 Step 1

Collect the items shown for the installation of your
particular engine.

 Step 3

Install the tapered aluminum adapter plate to the right side
of the engine with a short 1/4-20 bolt and AC nut through
the top mounting hole and don't tighten yet.

 Step 4

Measure, mark and drill firewall to correct dimensions and
offset to the left side.

 Step 2

Install the short aluminum adapter to the top left mounting
hole on the engine using the short 1/4-20 bolt and aircraft
nut. Don't tighten yet.

26

 Step 3

Use a drill and 5/16-inch (8mm) drill bit to drill the holes
in the firewall for mounting the engine.

 Step 5

Install the 1/4-20 blind nuts from the back side of the
firewall. You can use the bolts and standoffs to pull the
blind nuts into position.

 Step 6

Install engine using four 2
aluminum standoffs, one 3/16-inch (5mm) aluminum
spacers and four 1/4-20 x 4-inch socket head bolts and
four 1/4-inch lock washers.

7

/8-inch (73mm) machined

 Step 7

Cut the top of the motor box to mount the throttle servo as
photos and install it top down.

 Step 8

Drill a hole in the firewall for the throttle linkage to pass.

27

 Step 9

Install the (supplied) throttle linkage.

 Step 10

Attach the fuel line from the fuel tank to the carburetor.
Make sure the line is from the clunk and not the vent line.
Cut the line between the carburetor and fuel tank to install
a Fuel Dot (HAN115). This will make fueling the tank
much easier when the cowl is installed.

 Step 11

Secure the battery for the ignition inside the fuselage
using a hook and loop strap. Make sure to add a few
pieces of foam between the fuselage and battery to prevent
damage to the battery caused by vibration. Connect the
battery to the ignition switch. The EVO 116 requires a
3-cell Li-Po ignition battery.

 Step 12

Use 30-minute epoxy to glue in cover plate to the fuselage
for pipe tunnel.

 Step 13

Bolt the mufflers onto engine using the hardware provided
with the mufflers.

28

 Step 14

Make any necessary cutouts to clear the engine
components in the cowl. Remove a section from the
bottom of the cowling near the mufflers for cooling
outlet as shown. This opening is necessary to allow
cooling air to pass through the cowling to prevent
overheating of your engine.

 Step 15

Route the vent line from the fuel tank out the bottom
of the cowl.

29

Receiver Installation

Required Parts

• Fuselage assembly

• Hook and loop strap (4)

Required Tools and Adhesives

• Threadlock • Hobby knife

• Receiver • Switch harness

• 1/4-inch (6mm) foam) • Receiver battery

• Ignition battery

• 24-Inch Servo Lead Extension (JSP98040) (3)

• 36-inch Servo Lead Extension (JSP98050) (3)

IMPORTANT: Two receiver

batteries of at least 2700mAh or
larger are needed. Two 4000 2S2P
Li-Po receiver packs are shown.

Step 1



Install both receiver batteries with two layers of padded
2-sided servo tape and then secure in place with the
supplied hook and loop straps.

30

 Step 4

 Step 7

Use a hobby knife to remove the covering from the holes
in the sides of the fuselage for the two radio switches.

Secure any switches to the fuselage using the hardware
provided with the switches.

 Step 10

Put foam rubber or thick padded 2-sided tape under the
receiver. Use a hook and loop strap to secure the receiver
to the cross brace inside the fuselage. Plug the servos
into the receiver and route the servo leads neatly along the
side of the fuselage. Route the antenna wire (if necessary)
at this time as well.

31

Pilot and Canopy Installation

Required Parts

• Fuselage assembly • Pilot bust

• Canopy

Required Tools and Adhesives

• Canopy glue • Felt-tipped pen

• Painter's tape • Waxed paper

• 30-minute epoxy • Sandpaper

• Rubbing alcohol • Paper towel

 Step 1

Be sure the visor screws are tight. It is recommended to
remove the screws and use a drop of threadlock on them
to prevent vibrations from causing them to vibrate loose.

 Step 3

Trim the instrument panel from the decal sheet. Apply the
decal in position in the cockpit.

 Step 4

Position the canopy onto the hatch. Use a felt-tipped pen
to trace the outline of the canopy onto the hatch.

 Step 2

Use 30-minute epoxy to secure the pilot bust to the
canopy hatch.

 Step 5

Sand the hatch and canopy where they contact each other
using sandpaper. Clean the area using rubbing alcohol
and a paper towel.

32

 Step 6

Slip a piece of waxed paper between the hatch and
fuselage. Use canopy glue to attach the canopy to the
canopy hatch. Use painter's tape to keep the canopy in
position until the glue fully cures.

Radio Setup

A 7-channel or greater computer radio is highly

recommended. This allows the following features:

• Mixing the right aileron to the left aileron (flaperon mix)

• Electronically adjustable aileron differential

• Mixing the right elevator to the left elevator (dual

elevator mixing)

• Independent travel and trim adjustments for each

elevator half

When using a 7-Channel or greater computer radio,
each servo is plugged into its own separate channel.
Consult your radio manual for specific details on
hookup and programming.

33

Control Throws

Setting the control throws for your Extra 260 does require
some attention to detail. To correctly set the throws, it
is highly suggested to use the following procedure to
achieve the greatest mechanical advantage from your
servos.

 Step 1

Determine the maximum amount of control surface throw
from the throws listed. Use the high rate throws listed
to set the maximum amount of throw, then use your
computer radio for the lower rate listed.

 Step 2

Set the Travel Adjust (ATV on a Futaba transmitter) to

about 15% under the max. (On a JR transmitter, that
is 135%.) Make sure to set both directions during this
process.

 Step 3

Adjust the position of the clevis on the control horn and
position of the ball link on the servo arm to achieve the
throw decided in Step 1. It is highly recommended not to
change the position on the servo arm unless absolutely

necessary. Use Travel Adjust (ATV) to finalize the throws.

That is why we left a little margin in the percentages back
in Step 2.

 Step 4

If setting a dual elevator or aileron, match the linkage
locations used back in Step 3. Increase or decrease the

Travel Adjust (ATV) a few points as necessary to fine-tune

the throws to match up left and right sides and up and
down throws so all is symmetrical.

This is all necessary to tune the mechanical advantage as
good as possible. When setting up a model for 3D, the
mechanical advantage will be less because of the large
throws, and thus the servo will work harder and wear
faster. Using an insufficient servo for the job, or trying
to get too much throw, will cause something to give,
probably the servo.

There isn’t an exact geometry to the linkage, as it depends
on how much throw each individual modeler requires.
The linkage geometry should always be maximized so the
servo isn’t working any harder than it has to.

Aileron:

High Rate: 34.4 Degrees up, 54% Exponential

33 Degrees down, 54% Exponential

Low Rate: 23 Degrees up, 40% Exponential

22 Degrees down, 40% Exponential

Elevator:

High Rate: 48.5 Degrees up, 75% Exponential

47 Degrees down, 75% Exponential

Low Rate: 13 Degrees up, 45% Exponential

13 Degrees down, 45% Exponential

Rudder:

High Rate: 44 Degrees right, 50% Exponential

44 Degrees left, 50% Exponential

Low Rate: 30 Degrees right, 50% Exponential

30 Degrees left, 50% Exponential

Computer Radio Enhancements

A computer radio will allow you to do quite a bit of
fine-tuning to the feel of the Extra 260, which will make
aerobatics even easier.

34

Rates and Expos

Use Expo to soften the feel of the model. On high 3D
rates, use quite a bit of expo. The goal on 3D rates is to
get the model to feel the same around neutral as it does
on low rates.

Use low rate settings for all flying except for 3D
aerobatics. For precision flying or general sport hot­dogging, the low rate throws are perfect, even for snap
rolls. The only exception is rudder rates. Use 3D rudder
rate when doing stall turns and rolling circles, since
the more rudder the better for these. When doing 3D
aerobatics, flip to 3D rates just before the maneuver. As
soon as the maneuver is done, flip back down to low rate
to avoid over-controlling the model.

Recommended Center of Gravity (CG)

An important part of preparing the aircraft for flight is
properly balancing the model. This is especially important
when various engines are mounted.

Caution: Do not inadvertently skip this step!

The recommended Center of Gravity (CG) location for

your model is: 3

from leading edge of wing at the wing tip. Mark the
location of the CG onto the bottom of the wing using
a felt-tipped pen. With a helper, lift the aircraft with your
index finger at the location marked on the wing. Make
sure the aircraft is upright when checking the CG. If the
nose of your aircraft hangs low, add weight to the rear of
the aircraft. If the tail hangs low, add weight to the nose
of the aircraft. Stick-on weights are available at your local
hobby store and work well for this purpose.

1

/2 to 4 inches (89 to 102mm) back

35

Preflight

For those of you who are veterans of large models, this
is old news. But to you newcomers to the world of large
models, this is very important information.

While many smaller models are not critical of proper
battery use, and are tolerant of improper control linkage
setups and flying techniques, large models are not. Don’t
let that scare you away from large models; they are truly
one of the best flying experiences in RC that money
can buy. However, please pay particular attention to the
following areas.

Maintain the proper mechanical advantage on all
control surface linkages.

Just as with unsealed hinge gaps, mechanical advantage
is often another cause of flutter. Please follow the control
horn and servo arm lengths recommended in this manual.
Shorter arms on the servo or longer control horns on the
elevator and ailerons are fine, but do not try to go the
other way to increase throw. It can cause flutter or servo
failure on the Extra 260. The recommended linkage setups
are more than adequate to achieve full 3D throws.

Check the radio installation and make sure all the
control surfaces are moving correctly (i.e. the correct
direction and with the recommended throws). Test
run the engine and make sure it transitions smoothly
from idle to full throttle and back. Also ensure the
engine is tuned according to the manufacturer’s
instructions, and it will run consistently and constantly
at full throttle when adjusted.

Check all the control horns, servo horns, and clevises to
make sure they are secure and in good condition. Replace
any items that would be considered questionable. Failure
of any of these components in flight would mean the loss
of your aircraft.

While many smaller models are very tolerant of improper
control linkage setups and flying techniques, large models
are not. Don’t let that scare you away from large models;
they are truly one of the best flying experiences in RC that
money can buy. However, please pay particular attention to
the following areas.

Never attempt to make full throttle dives!

Large models perform much more like full-size aircraft
than small models. If the airframe goes too fast, such as
in a high throttle dive, it may fail. The Extra 260 should be
flown like a full-scale Extra 260. Throttle management is
absolutely necessary.

Hardware checks

Double-check the setscrews in all contol horns to be sure
they are very tight. Periodically check these to be sure
they have not loosened over time. Always use threadlock
on metal-to-metal fasteners.

Receiver Battery Selection

Be sure adequate batteries are used to power the receiver.
It is STRONGLY recommended that two identical 6-volt
receiver packs are used. Each pack must have a minimum
of 2700mAh capacity. Use packs of 3000mAh when super
high torque servos are used.

Servo selection

Be sure all servos used on elevator, aileron and rudder are
metal geared type and have at least 188 oz in of torque.
Failure to do this will very likely result in a failure and
loss of the model.

Range check

Always range check the radio system per the
manufacturer's instructions before the initial test flight and
periodically afterward.

Check the voltage of the on-board packs

ALWAYS use an ESV with a 1-amp load to check the

receiver battery packs and the ignition pack before each
and every flight. If there is any doubt that the packs are
questionable, DO NOT FLY until the packs are recharged.

36

Instructions for Disposal of WEEE by
Users in the European Union

This product must not be disposed of with other waste.
Instead, it is the user’s responsibility to dispose of their
waste equipment by handing it over to a designated
collection point for the recycling of waste electrical
and electronic equipment. The separate collection and
recycling of your waste equipment at the time of disposal

will help to conserve natural resources and ensure that it
is recycled in a manner that protects human health and
the environment. For more information about where you
can drop off your waste equipment for recycling, please
contact your local city office, your household waste
disposal service or where you purchased the product.

37

2007 Official AMA

National Model Aircraft Safety Code

GENERAL

1. A model aircraft shall be defined as a non-human­carrying device capable of sustained flight in the
atmosphere. It shall not exceed limitations established
in this code and is intended to be used exclusively for
recreational or competition activity.

2. The maximum takeoff weight of a model aircraft,
including fuel, is 55 pounds, except for those flown
under the AMA Experimental Aircraft Rules.

3. I will abide by this Safety Code and all rules
established for the flying site I use. I will not willfully
fly my model aircraft in a reckless and/or dangerous
manner.

4. I will not fly my model aircraft in sanctioned events,
air shows, or model demonstrations until it has been
proven airworthy.

5. I will not fly my model aircraft higher than
approximately 400 feet above ground level, when
within three (3) miles of an airport without notifying the
airport operator. I will yield the right-of-way and avoid
flying in the proximity of full-scale aircraft, utilizing a
spotter when appropriate.

6. I will not fly my model aircraft unless it is identified
with my name and address, or AMA number, inside or
affixed to the outside of the model aircraft. This does
not apply to model aircraft flown indoors.

7. I will not operate model aircraft with metal-blade
propellers or with gaseous boosts (other than air),
nor will I operate model aircraft with fuels containing
tetranitromethane or hydrazine.

8. I will not operate model aircraft carrying pyrotechnic
devices which explode burn, or propel a projectile
of any kind. Exceptions include Free Flight fuses or
devices that burn producing smoke and are securely
attached to the model aircraft during flight. Rocket
motors up to a G-series size may be used, provided
they remain firmly attached to the model aircraft during
flight. Model rockets may be flown in accordance with
the National Model Rocketry Safety Code; however,
they may not be launched from model aircraft. Officially
designated AMAAir Show Teams (AST) are authorized
to use devices and practices as defined within the Air
Show Advisory Committee Document.

9. I will not operate my model aircraft while under the
influence of alcohol or within eight (8) hours of having
consumed alcohol.

10. I will not operate my model aircraft while using any
drug which could adversely affect my ability to safely
control my model aircraft.

11. Children under six (6) years old are only allowed on
a flightline or in a flight area as a pilot or while under
flight instruction.

12. When and where required by rule, helmets must be
properly worn and fastened. They must be OSHA, DOT,
ANSI, SNELL or NOCSAE approved or comply with
comparable standards.

38

2007 Official AMA

National Model Aircraft Safety Code

Radio Control

1. All model flying shall be conducted in a manner to
avoid over flight of unprotected people.

2. I will have completed a successful radio equipment
ground-range check before the first flight of a new or
repaired model aircraft.

3. I will not fly my model aircraft in the presence of
spectators until I become a proficient flier, unless I am
assisted by an experienced pilot.

4. At all flying sites a line must be established, in front of
which all flying takes place. Only personnel associated
with flying the model aircraft are allowed at or in front
of the line. In the case of airshows demonstrations
straight line must be established. An area away from
the line must be maintained for spectators. Intentional
flying behind the line is prohibited.

5. I will operate my model aircraft using only radio­control frequencies currently allowed by the Federal
Communications Commission (FCC). Only individuals
properly licensed by the FCC are authorized to operate
equipment on Amateur Band frequencies.

6. I will not knowingly operate my model aircraft within
three (3) miles of any preexisting flying site without
a frequency-management agreement. A frequency­management agreement may be an allocation of
frequencies for each site, a day-use agreement between
sites, or testing which determines that no interference
exists. A frequency-management agreement may exist
between two or more AMA chartered clubs, AMA
clubs and individual AMA members, or individual
AMA members. Frequency-management agreements,
including an interference test report if the agreement
indicates no interference exists, will be signed by all
parties and copies provided to AMA Headquarters.

7. With the exception of events flown under official AMA
rules, no powered model may be flown outdoors closer
than 25 feet to any individual, except for the pilot and
located at the flight line.

8. Under no circumstances may a pilot or other person
touch a model aircraft in flight while it is still under
power, except to divert it from striking an individual.

9. Radio-controlled night flying is limited to low­performance model aircraft (less than 100 mph).
The model aircraft must be equipped with a lighting
system which clearly defines the aircraft's attitude and
direction at all times.

10. The operator of a radio-controlled model aircraft shall
control it during the entire flight, maintaining visual
contact without enhancement other than by corrective
lenses that are prescribed for the pilot. No model
aircraft shall be equipped with devices which allow it
to be flown to a selected location which is beyond the
visual range of the pilot.

39

10492.1

© 2007 Horizon Hobby, Inc.

4105 Fieldstone Road

Champaign, Illinois 61822

[phone]

horizonhobby.com