Hangar 9 Extra 300 User Manual
35% Extra 300 ARF
Assembly Manual
Notice
All instructions, warranties and other collateral
documents are subject to change at the sole discretion
of Horizon Hobby, Inc. For up-to-date product
literature, visit http://www.horizonhobby.com and click
on the support tab for this product.
Meaning of Special Language
The following terms are used throughout the product
literature to indicate various levels of potential harm
when operating this product:
NOTICE: Procedures, which if not properly followed, create
a possibility of physical property damage AND a little or no
possibility of injury.
CAUTION: Procedures, which if not properly followed,
create the probability of physical property damage AND a
possibility of serious injury.
WARNING: Procedures, which if not properly followed,
create the probability of property damage, collateral damage,
and serious injury OR create a high probability of superficial
injury.
WARNING: Read the ENTIRE instruction manual to
become familiar with the features of the product before
operating. Failure to operate the product correctly can result
in damage to the product, personal property and cause
serious injury.
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.
Do not attempt disassembly, use with incompatible
components or augment product in any way without the
approval of Horizon Hobby, Inc. This 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 serious injury.
Table of Contents
Intro ................................................................................. 2
Product Support ..............................................................2
Specifications ................................................................... 2
Included Parts ................................................................. 3
Contents of Kit and Parts Number .................................... 4
Safety Precautions and Warnings .................................... 4
35% Extra 300 Operating Recommendations ..................5
Important Information Regarding Warranty .....................5
Using the Manual ............................................................. 5
Aileron Servos Installation ............................................... 7
Elevator Servo Installation ............................................. 11
Rudder Installation ......................................................... 13
Tail Wheel Assembly Installation .................................... 14
Rudder Servo Installation .............................................. 15
Main Gear and Wheel Pants Installation ......................... 17
Engine and throttle Servo Installation ............................19
In-Cowl Mufflers Installation ..........................................22
Canisters Installation ...................................................... 23
Tuned Pipe Installation .................................................. 25
Receiver and Ignition Battery Installation ....................... 28
Ignition Module, Switch and Regulator Installation ........ 29
Fuel Tank, Fill and Over Flow Installation ........................31
Cowl Mounting ............................................................... 33
Pilot Installation ............................................................. 33
Receiver, Switch and throttle Servo
Regulator Installation ..................................................34
Satellite Receivers Installation ....................................... 36
Center of Gravity ............................................................ 37
Control Throws .............................................................. 37
Applying Decals .............................................................38
Preflight ......................................................................... 39
Range Test Your Radio ................................................... 39
Safety Do’s and Don’ts for Pilots ....................................39
Daily Flight Checks ......................................................... 39
Warranty and Repair Policy ............................................ 40
Warranty Services .......................................................... 40
Compliance Information for the European Union ........... 41
2011 Official Academy of
Model Aeronautics Safety Code .................................42
Intro
Pulling from the success of its predecessor, designer Mike
McConville built on strengths of the popular 35% Extra 260
to create the new Extra 300, which is undoubtedly his best
Extra design yet.
With improved aerodynamic design, and a completely
reengineered structure, the Extra 300 offers straight and true
flight performance in an airframe designed to stand up to the
most extreme acrobatic routines.
Ideal for IMAC competition, freestyle flying or extreme 3D,
the Extra will not disappoint.
Finished in a new trim scheme from the creative mind of
Mike Hilderbrandt, the Extra is as visible in the air as it is
beautiful on the tarmac.
All guess work has been taken out of this ARF— the most
popular engine and exhaust choices are covered in this
manual.
The Hangar 9® 35% Extra 300 sets a new standard for giant
—scale: ease of assembly and world class performance.
Enjoy your new 300 and many happy landings.
Product Support
For technical assistance with this product, please contact the
appropriate Horizon Product Support office.
Specications
Wingspan 105 in (2.7 m)
Length 98.0 in (2.5 m)
Wing Area 2003 sq in (129.2 sq dm)
Weight 27.0–30.0 lb (12.2–13.6 kg)
Transmitter & Servos
4-channel (or greater) with 8 servos
Engine 100cc - 120cc gas engine
2 35% Extra 300 ARF Assembly Manual2
PACKAGED IN KIT
Fuselage with hinged rudder 1
Right horizontal stabilizer with hinged elevator 1
Left horizontal stabilizer with hinged elevator 1
Wings with hinged aileron 1
Cowl 1
HARDWARE BAGS
Included Parts
Engine standoffs and bolts
Ball Links include 4-40 screws, locknuts and conical spacers
Pushrods
335% Extra 300 ARF Assembly Manual
21
8
2
Safety Precautions and Warnings
10
1
15
9
4
3
14
5
13
6
7
Read and follow all instructions and safety precautions
before use. Improper use can result in fire, serious injury
and damage to property.
COMPONENTS
Use only with compatible components. Should any
compatibility questions exist please refer to the product
instructions, the component instructions or contact Horizon
Hobby, Inc.
FLIGHT
Fly only in open areas to ensure safety. It is recommended
flying be done at AMA (Academy of Model Aeronautics)
approved flying sites. Consult local ordinances before
choosing a flying location.
PROPELLER
Keep loose items that can get entangled in the propeller
away from the prop, including loose clothing, neck strap or
other objects such as pencils and screwdrivers. Especially
keep your hands away from the propeller as sever injury can
occur. Using a thick glove is highly recommended.
BATTERIES
Notes on Lithium Polymer Batteries
Contents of Kit and Parts Number
Replacement Parts
1. HAN105501 Fuselage w/Hatch 35% Extra 300 ARF
2. HAN105502 Hatch w/Canopy, 35% Extra 300 ARF
3. HAN105503 Left Wing Panel, 35% Extra 300 ARF
4. HAN105504 Right Wing Panel, 35% Extra 300 ARF
5. HAN105505 Left Stab Panel, 35% Extra 300 ARF
6. HAN105506 Right Stab Panel, 35% Extra 300 ARF
7. HAN105507 Rudder w/Horn, 35% Extra 300 ARF
8. HAN105509 Painted Cowl, 35% Extra 300 ARF
9. HAN105510 Wheel Pant Set, 35% Extra 300 ARF
10. HAN105511 Painted Landing Gear, 35% Extra 300 ARF
11. HAN105512 Linkage Hdwr Set, 35% Extra 300 ARF
12. HAN105513 Assembled Gas Tank, 35% Extra 300 ARF
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Replacement Parts
13. HAN105514 Carbon Wing Tube, 35% Extra 300 ARF
14. HAN105514 Carbon Stab Tube, 35% Extra 300
15. HAN105515 Tailwheel Unit, 35% Extra 300 ARF
16. HAN105516 Main Axle Set, 35% Extra 300 ARF
17. HAN105517 Exh/Batt Mount Set, 35% Extra 300 ARF
18. HAN105518 Cowl/Canopy Screws; 35% Extra 300 ARF
19. HAN105519 Decal Set, 35% Extra 300 ARF
20. HAN105520 Nylon Wing Bolts, 35% Extra 300 AEF
21. HAN376 35% Painted Pilot Helmet Extra 300
When misused Lithium Polymer batteries are significantly
more volatile than alkaline or Ni-Cd/Ni-MH batteries used
in RC applications. Always follow the manufacturer’s
instructions when using and disposing of any batteries.
Mishandling of Li-Po batteries can result in fire and rupture
causing serious injury and damage.
SMALL PARTS
This kit includes small parts and should not be left
unattended near children as choking and serious injury could
result.
Age Recommendation:
For advanced fliers ages 14 and above. This is not a toy.
35% Extra 300 Operating Recommendations
• Inspectyourmodelbeforeeveryflighttomakecertainit
is airworthy.
• Beawareofanyotherradiofrequencyuserwhomay
present an interference problem.
• Alwaysbecourteousandrespectfulofotherusersof
your selected flight area.
• Chooseanareaclearofobstaclesandlargeenoughto
safely accommodate your flying activity.
• Makecertainthisareaisclearoffriendsandspectators
prior to launching your aircraft.
• Beawareofotheractivitiesinthevicinityofyourflight
path that could cause potential conflict.
• Carefullyplanyourflightpathpriortolaunch.
• AbidebyanyandallestablishedAMANationalModel
Aircraft Safety Code.
Important Information
Regarding Warranty
Please read our Warranty and Liability Limitations section
before building this product. 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.
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 () are performed once, while
steps with two or more boxes () indicate that the step
will require repeating, such as for a right or left wing panel,
two servos, etc. Remember to take your time and follow the
directions.
UltraCote® Covering Colors
•White HANU870
•TrueRed HANU866
•Silver HANU881
Recommended Setup–2-Stroke Gas
•DA100
•DA-120
Recommended Spinner
4 1/2-inch silver Tru-Turn Ultimate Style with solid
backplate.
•DA120,TT-4552-B-M-DA120(2-BladedProp)
•DA120,TT-4553-B-M-DA120(3-BladedProp
Optional Tuned Pipe and Canister
Installation
If you are installing the optional tuned pipe, the following
items will be required:
•50mmdropheader,111/2-inchlongfortunedpipe
(MTW, RE2) and 10-inch for canister (MTW TD75)
•Clamps
•Couplers
Transmitter Requirements
The 35% Extra 300 requires a minimum of a 4-channel radio
to operate all the functions of your aircraft. However to get
the best performance from the Extra, a radio with mixing
functions is recommended. We suggest the following radio
system available through Horizon Hobby or your local hobby
distributor.
Spektrum DX8 SPM8800
Spektrum DX10t SPM2800US SPM2800
JR DSM2 or DSMX systems
Radio Equipment Requirements
The following items are recommended when installing the
9-Channel AR9110 (SPMAR9110) in your aircraft:
DS8911HV Digital Servo (7) JRPS8911HV
JR 537 Servo (1) JRPS537
3-inch Servo Extension (1) (Regulator) JSP98100
18-inch Servo Extension (2) (RX to Ailerons) JRPA099
24-inch Servo Extension (1) (Throttle) JRPA102
24-inch Servo Extension (2) (Ailerons) JRPA102
24-inch Servo Extension (1) (Rudder) JRPA102
36-inch Servo Extension (2) JRPA103
(2) Receiver Packs, 4000mAh Spektrum SPMB4000LP
Ignition Pack 2000mAh Spektrum SPMB2000LP
JR Charge Switch JRPA004
JR MatchBox (2) JRPA900
JR 5203 Regulator (2) JRPVR5203
535% Extra 300 ARF Assembly Manual
Additional Required Tools
Additional Required Adhesives
Rotary too
Cut-off wheel Sanding drum
Drill Epoxy brush
Felt-tipped pen Ruler
Hex wrench: 1.5mm, 3mm, 4mm, 4.5mm, 3/32-inch, 5/32-
inch Iron
Hobby knife with #11 blade Mixing cup
Mixing stick Paper towel
Pencil Hemostat
Shoo Goo or Zap-A-Dap-A-Goo
Phillips screwdriver: #1, #2 Pin vise
Vise grip Masking tape
Rubbing alcohol
Nut driver: 1/4-inch, 1/2-inch, 9mm
Heat gun
Drill bit: 1/16-inch (1.5mm), 5/64-inch (2mm),
3/32-inch (2.5mm), 3/16-inch (5mm), 1/4-inch
(6.35mm)
Medium CA (PAAPT02)
Thin CA (PAAPT08)
CA remover/debonder (PAAPT16)
CA accelerator (PAAPT15)
Blue Threadlock (PAAPT42)
30-Minute Epoxy, 8 oz (PAAPT39)
Before Starting Assembly
Before beginning the assembly of your model, 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
covering iron to remove them. Use caution while working
around areas where the colors overlap to prevent separating
the colors.
HAN100 – Heat Gun
HAN150 – Covering Glove
HAN101 – Sealing Iron
HAN141 – Sealing Iron Sock
6 35% Extra 300 ARF Assembly Manual
Aileron Servos Installation
Required Parts
Wing panel Ball link (4)
Control horns (4)
Aileron pushrod (4)
Required Parts (not included)
JR 8911HV with hardware (4) or similar digital servo
JR 1-1/4-inch servo arm (4)
JR heavy-duty servo extension, 24-inch (2)
JR MatchBox™ (2)
Required Tools and Adhesives
Pin vise
Thin CA Phillips screwdriver: #1
Drill bit: 1/16-inch Masking tape
Adhesive-backed hook and loop
3/32-inch ball driver Scissors
Dental floss (string)
1. Prepare the aileron servos by installing the rubber
grommets and brass eyelets.
Hint: Prepare all servos for the wing at this time.
3. Apply a piece of masking tape around the connector
and over the string.
5. Mount the servo so the output shaft is facing toward
the trailing edge and mark the servo mounting lugs location.
2. Secure a 24-inch servo extension to the outboard
aileron servo lead using string or a commercially available
connector. This will prevent the extension from accidentally
disconnecting inside the wing.
4. A string has been installed in the wing to pull the
aileron servo extension through the wing. Tie or tape the
string to the end of the extension and pull the lead to the
wing root.
6. Remove the servo. Using a pin vise, drill the servo
mounting screw locations.
7. In order to harden the servo mounting holes in
the bays, mount the servo screws, back them out and
apply some thin CA in the hole. Wait until CA is dry before
735% Extra 300 ARF Assembly Manual
installing the servo.
11. Screw on the control horn so the distance from
the hinge line to the center of the pivot point measures 1
1/2-inch.
Order of ball link assembly is bolt through the ball link,
conical spacer with flat end facing the servo arm, servo arm
and then nut.
8. Install the servo.
10. Attach the linkage to control horn and ball link.
12. Attach the ball link to 1 1/4-inch servo arm hole; in
case of JR servo arm, this is the second outermost hole.
9. Prepare the linkages and servo arm for outboard
servo installation.
13. Connect the servo to the MatchBox and receiver,
with radio sub-trim at 0, install the servo arm onto the servo
8 35% Extra 300 ARF Assembly Manual
on the spline that gets it as close to parallel to the hinge line
as possible. If necessary, use the sub trim in the transmitter
to adjust the neutral position so the arm is parallel to the
hinge line. Attach the linkage to the servo arm and adjust the
length using a Hangar 9 Pro-Link™ adjustment tool so the
aileron is at the neutral position.
14. Apply a drop of threadlock on the servo arm center
screw and tighten.
18. Assemble the servo linkage following the same
steps as the outboard servo. Make sure to set the distance of
center of the control horn pivot to the aileron hinge at 1 1/2
inch.
16. Mount the inboard servo following the same
method as outboard but no extension is required. Tie a knot
using the string that has been attached to the servo bay and
pull the servo lead through the root rib as shown.
19. Connect the servo to the Matchbox and refer to the
MatchBox Programming Hints on page 10 for final setup.
15. Tighten the servo arm setscrews. Do not use
threadlock on these screws.
17. Mount the servo so that the output shaft is toward
the trailing edge. Follow the same steps in marking and
making the servo mounting holes as the outboard servo.
20. The picture below shows both servos installed.
935% Extra 300 ARF Assembly Manual
21. Apply a piece of masking tape to the back of the
MatchBox.
22. Glue a piece of hook and loop using CA to the
masking tape.
24. Connect the inboard and outboard servo leads to the
MatchBox and mount the MatchBox in the root.
MatchBox Programming Hints
The pointers below can help make matching servos easier.
This is not to take the place of the MatchBox instruction
manual.
1. Connect the outboard servo to the MatchBox and then
make all adjustments to servo center and travel adjustments
in the transmitter programming. No adjustments to this
servo should be made in the MatchBox.
2. Connect the inboard servo to the MatchBox, then
install the servo arm onto the servo on the spline that gets
it as close to parallel with the hinge line as possible. Then
use the MatchBox to set the center of this servo so the
servo arm is exactly parallel to the hinge line. Now adjust the
linkage length so the hole in the ball link directly aligns with
the appropriate hole in the servo arm.
Deflect the servo to full stick in one direction and use the
MatchBox to set the endpoint so the ball link directly lines
up with the hole in the servo arm. Repeat this with the stick
fully deflected in the opposite direction. Once the center and
both endpoints are set for the second servo, remember to
turn the dial on the MatchBox back to the 0 position to save
the settings before powering off the receiver. Hint, when
adjusting for endpoints (full deflection), it is hard to hold the
sticks and adjust the MatchBox at the same time. It is best to
move the sticks to full deflection and while holding the stick,
turn off the radio. This will put the receiver into hold and
makes adjustment easier working only the MatchBox and
observing the linkage position over the servo arm.
23. Glue opposite side of hook and loop using CA to
the root of the wing panel.
10 35% Extra 300 ARF Assembly Manual
Elevator Servos Installation
Required Parts
Elevator panel
Ball link (2)
Control horns (2)
Elevator pushrod (2)
Required Parts (not included)
JR 8911HV or similar digital servo (2)
JR 1 1/2-inch servo arm (2)
JR heavy-duty servo extension, 36-inch (2)
Required Tools and Adhesives
Pin vise
Thin CA Phillips screwdriver: #1
Drill bit: 1/16-inch Masking tape
String (Dental floss)
3/32-inch ball driver
Note: It is important to go over the covering with
covering iron and make sure all the seams are sealed.
3. Using a pin vise, drill the servo mounting screw.
5. Secure a 36-inch JR Heavy-Duty extension using a
string or commercially available safety connector.
1. Prepare the servo by installing the rubber grommets
and brass eyelets.
The servo needs to be installed in such a way that the output
shaft is towards the leading edge of the stab. The servo arm
needs to be 1 1/2 inch. If using a JR aluminum servo arm,
this would be the third outermost hole.
2. Mount the servo and mark the servo mounting
holes.
4. In order to harden the servo mounting holes in
the bays, mount the servo screws, back them out and
apply some thin CA in the hole. Wait until CA is dry before
installing the servo.
6. Apply a piece of masking tape over the knot holding
the leads.
7. For removable stab setup, do not connect the
extension to the elevator servo, instead run a 36-inch
extension through the fuselage and exit from stab mounting
1135% Extra 300 ARF Assembly Manual
hole. Use a commercially available safety connector instead
of the string and masking tape to secure the connector.
8. Mount the servo so that the output shaft is closer to
the leading edge of the elevator. Pass the extension through
the slot provided in the root of the elevator panel.
9. Prepare the linkage and control horn for installation.
10. Screw on the control horn so that the distance
from the elevator hinge line to the center of the pivot point of
the horn is 1 3/8 inch.
12. Mount the servo arm so it is perpendicular to
the center line of the stab, make adjustment to sub-trim if
necessary.
11. Power up the servo by connecting it to the receiver. With
The picture below shows the slot that extension needs to exit
from.
12 35% Extra 300 ARF Assembly Manual
radio sub-trim set at 0.
13. Apply a drop of threadlock to the servo center
screw and tighten the screw. This is the outer hole in the JR
Aluminum arm.
15. Connect the ball link to 1 1/2-inch servo arm. In
case of JR Aluminum servo arm, this is the outermost hole.
Insert the ball link screw into the ball link through the conical
spacer (flat surface facing the arm) and servo arm and then
nut.
Rudder Installation
Required Parts
Fuselage Rudder
Hinge rod
Required Tools and Adhesives
Drill Pliers
Petroleum Jelly/Industrial lubricant
1. Apply some industrial lubricant to the rod. Pass the
rod through the hinges in the rudder and fuselage vertical fin
separately. This helps remove any possible dirt in the hinges
and makes for easier final assembly.
14. Tighten the servo arm setscrews. Move the servo
arm all the way to the front and back to access the mounting
lugs.
16. With servo arm perpendicular to the center line
of the stab, use a Hangar 9 Pro-Link Wrench to adjust the
linkage so the elevator is at neutral position.
2. Mate the rudder and fuselage vertical stabilizer
and carefully pass the rod through hinges. This can be
accomplished by two ways. 1. Use a drill on slow speed
and gently pass through the rod. If there is any resistance,
back out and repeat. 2. Use a pair of pliers and push the rod
through the hinges. Make sure not to buckle the rod. This is
a rather slow process and needs attention.
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Tail Wheel Assembly Installation
Required Parts
Tail gear and screws Springs
T-bracket and screws
Required Tools and Adhesives
2.5mm and 7/64-inch ball driver
Blue threadlock Felt-tipped pen
Thin CA Pin vise
3. Cut excess rod long enough (1mm) that it is easy to
grab and pull out when needed for transportation. The tail
wheel bracket will stop the rod from backing out of the
hinges.
The picture below shows the rod when cut.
1. Mount the T-bracket so it is parallel to the rudder horn
bolt and mark using a felt-tipped pen.
2. Using a pin vise, drill the marked spots.
4. To harden the wall, apply some thin CA into the holes.
Wait until CA is dry before installing the T-bracket.
3. Mount the sheet metal screws provided and back them
out.
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5. Apply threadlock to the tail gear bolts.
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