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