Hangar 9 Extra 330L Instruction Manual

INSTRUCTION MANUAL

TM

Specifications

Wingspan: . . . . . . . . . . . . . . . . . . . . . . . 97 in . . . . . . 2,463.8 mm

Fuselage Length: . . . . . . . . . . . . . . . . . 88 in . . . . . . 2,235.2 mm

Wing Area: . . . . . . . . . . . . . . . . . 1,750 sq in . . . . . . . . 112.9 dm

2

Flight Weight: . . . . . . . . . . . 23.5to 26.5 lb . . . 9.98–11.80 kg

Recommended Engines: . . . . . . 60 to 80 cc

• 90% custom built

• Designed by 7-time TOC
competitor Mike McConville

• Specifically designed for excellence
in precision and 3D aerobatics

• Prepainted fiberglass cowl
and wheelpants

• Plug-in wing and stab

• Precover ed with gen uine
Goldberg UltraCote

®

• IMAC and IMAA legal

• Instructions include 3D flying tips from Mik e McCon ville

TM

WE GET PEOPLE FLYING

2

Table of Contents

Introduction ..................................................................................................................................................................................... 2

Warning ..................................................................................................................................................................................... 3

Additional Equipment Required ............................................................................................................................................................ 3

Other Items Needed (not included in the kit) ......................................................................................................................................... 4

Tools and Supplies Needed (not included in the kit) ............................................................................................................................. 4

Contents of Kit ......................................................................................................................................................................................5

Section 1. Installing the Aileron Servos ............................................................................................................................................. 6

Section 2. Installing the Aileron Control Horns .................................................................................................................................. 7

Section 3. Hinging and Sealing the Control Surfaces .........................................................................................................................9

Section 4. Installing the Linkages .................................................................................................................................................... 13

Section 5. Installing the Rudder and Elevator Servos ....................................................................................................................... 14

Section 6. Installing the Elevator, Control Horns, and Linkages ....................................................................................................... 16

Section 7. Installing the Rudder, Control Horns, and Linkages ........................................................................................................ 19

Section 8. Installing the Landing Gear ............................................................................................................................................. 21

Section 9. Attaching the Tail Wheel .................................................................................................................................................. 24

Section 10. Installing the Receiver, Battery, and Fuel Tank ................................................................................................................. 25

Section 11. Mounting the Engine and Cowl ....................................................................................................................................... 27

Section 12. Hatch Assembly ..............................................................................................................................................................30

Section 13. Balancing the Model ....................................................................................................................................................... 31

Section 14. Radio Setup ..................................................................................................................................................................... 32

Section 15. Control Throws ...............................................................................................................................................................32

Preflight at the Field ...........................................................................................................................................................................32

Setup and Flight Tips by Mike McConville .........................................................................................................................................33

AMA Safety Code ............................................................................................................................................................................... 39

Introduction

Thank you for your purchase of Hangar 9’s Extra 330L. Because the size and weight create a higher degree for potential danger, an
added measure of care and responsibility is needed when building and flying giant-scale models. If this is your first giant-scale
aerobatic aircraft, it’s important that you carefully follow the instructions, especially those regarding hinging (pages 9–10), sealing the
hinge gaps (pages 11–12), and the section on flying (pages 33).

Like all giant-scale aerobatic aircraft, the Extra requires powerful, heavy-duty servos. Servos greatly effect the flight performance, feel,
and response of the model. To get the most out of your Extra, it’s important to use accurate, powerful servos with a minimum of 80 oz/in
of torque. In the prototype models we used JR 8101s and JR 8411s with excellent results. A less powerful servo can lead to a crash.

The Extra 330L does not include hardware. Many experienced giant-scale pilots have specific hardware preferences and can
individually choose the components that they prefer. Hangar 9 offers an optional hardware package (page 5) part (#HAN1220, JR/
#HAN1221, FUT) that includes the hardware that our staff regularly uses and recommends.

Throughout the manual, the above hardware will be used during the assembly process. If using another type/brand of hardware, it’s
your responsibility to be sure that it’s strong enough for this application and properly installed.

If you encounter difficulty in any construction sequence, please contact one of our technicians. We stand ready to provide any
assistance we can concerning the construction of your Extra 330L. Contact us at:

Horizon Hobby, Inc.
4105 Fieldstone Road, Champaign, IL 61822
[phone] www.horizonhobby.com

Warning

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open areas, preferably
AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included with your radio and engine.

Additional Equipment Required

Radio Equipment with Computer Radio

• (7) Servos with 80 oz/in of torque minimum (JR8101, 4721, 2721, or 8411 or equivalent)

• 1000mAh receiver battery pack or larger

• (4) 24" Servo Extensions (JRPA102)

• (1) 18" Servo Extensions (JRPA101)

• (2) 6" Servo Extensions (JRPA095)

• (2) 12" Servo Extensions (JRPA099)

Radio Equipment Non-Computer Radio

• (7) Servos with 80 oz/in of torque minimum (JR8101, 4721, 2721, or 8411 or equivalent)

• (3) Y-Harnesses (JRP133)

• (4) 18" Servo Extensions (JRPA101)

• 1000mAh receiver battery pack or larger

• (2) 12" Servo Extensions (JRPA099)

• (2) 6" Servo Extensions (JRPA095)

Note: Requires one reversed servo for elevator

Recommended JR Systems:

• JR 400EX

• JR 421EX

• JR XP652

• JR XP783

• JR XP8103

• JR PCM10X

Engine Requirements

• 60-80 cc Gasoline Engine

Recommended Gasoline Engines:

• Zenoah G-62 Gasoline Engine

• Zenoah GT-80 Gasoline Engine

3

JR 8103

Zenoah G-62

Zenoah GT-80

4

Other Items Needed (not included in the kit)

Zenoah Gas Start-up Package (ZEN20002) Includes:

• Kill Switch (ZEN20000)

• Oil (2 Cycle) (ZEN20001

• Fuel Dot (HAN115)

• Fuel Filter (HAN143)

• Mix Cup (HAN3101)

• Gas Stopper (DUB400)

• 3' Fuel Line (DUB799)

• Line keeper (DUB677))

T ools and Adhesives Needed (not included in the kit)

Tools

• Drill

• Drill bits: 1/16", 1/8", 5/32", 1/4", 3/8", 1/2", 5/16"

• Medium Phillips screwdriver

• Small straight screwdriver

• Needle-nose pliers

• Hobby knife with #11 blade

• Mixing stick

• Straight edge

• Jig saw

• Soldering iron

• Measuring device (e.g., ruler, tape measure)

• Scissors

• Moto-tool with cut-off wheel

• 8-32 Tap (DUB363)

• Sealing iron

• Glue syringe or tooth pick

•5/32" and 1/8" Hex wrench

• Adjustable wrench

Addition Needed Items

• 4" spinner

• Propeller

(Refer to recommendations listed in your engine’s
operating instructions.)

• 2' gas compatible tubing

• Cup engine mount B+B 6202 (G-62 only)

• Coarse sandpaper

• Radio packing foam

• Antenna tube

•1/8" light plywood

• (4) 1/4"-20 x 1/4" Socket head screws (G-62 only)

• 1/3 Scale Pilot (HAN8265)

• (2) Small cable ties

• Paper towels

Adhesives

• Thick CA (cyanoacrylate) glue

• CA remover/debonder

• 30-minute epoxy

• 5-minute epoxy

• Silicon glue

• Canopy glue

• Blue Locktite

®

• Electrical tape

• Masking tape

• Rubbing alcohol

• Felt-tipped pen/pencil

• White UltraCote

®

(GBG870)

• Pearl Blue UltraCote®(GBG845)

5

• Fuselage (HAN1201)

• Right Wing Panel with Aileron (HAN1202)

• Left Wing Panel with Aileron (HAN1203)

• Right Horizontal Stabilizer and Elevator (HAN1204)

• Left Horizontal Stabilizer and Elevator (HAN1205)

• Landing Gear Fairing (HAN1216)

• Rudder (HAN1208)

• Wing Tube (HAN1206)

• Stabilizer Tubes (2) (HAN1207)

• Canopy (HAN1209)

• Canopy Hatch (HAN1210)

• Fiberglass Painted Cowl (HAN1211)

• Wheel Pants (HAN1212)

• Landing Gear (HAN1213)

Contents of Kit

Note: Photos of products may vary slightly from the contents in the box.

•31/2" Wheels (2) (DUB350L)

•41/2" 4-40 Threaded Pro-Links (4) (HAN3556)

• 5" 4-40 Threaded Pro-Links (2) (HAN3557)

• 32 oz Fuel Tank (DUB690)

• Tail Wheel Assembly with Hardware (OHI130)

• 4-40 Ball Links (7) (ROC87)

• 8-32 Swivel Control Horns (6) (ROC01B)

• 4-40 Rod, Threaded one end (6) (DUB802)

•

3

/16" Main Axles (DUB249)

• Super Hinge Points (24) (ROB309)

• 4-40 1/2 3D Arm (11/4") JR (2) (HAN3578)

• 4-40 1/2 HD Arm (1") JR (4) (HAN3574)

• 4-40 1/2 3D Arm (11/4") Futaba (2) (HAN3579)

• 4-40 1/2 HD Arm (1") Futaba (4) (HAN3575)

• 4-40 Solder Link (2) (DUB305)

•3/16" Wheel Collars (2) (DUB141)

Included in the optional Hangar 9 1/3 Scale Hardware Package (HAN1220,JR/HAN1221, Futaba)

Replacement Parts

6

The ailerons require a minimum of 80 oz/in of servo torque. In
the prototype Extras, we used JR8101 and JR8411 servos.
JR’s 8411s offer a crisp response — the ultimate servo choice.

JR8101 Ultra Precision Wide Bearing

Torque: 90.4 oz/in Speed: .23 sec/60°
Weight: 1.5 oz Size: .73" x 1.52" x 1.32"
Motor: Coreless Ball Bearing: Dual

JR8411 Digital Ultra Torque

Torque: 155 oz/in@

4.8V Speed: .18 sec/60°
Weight: 2.03 oz Size: .73" x 1.52" x 1.32"
Motor: Coreless Ball Bearing: Dual

Step 1. Install the servo hardware (grommets and eyelets)
included with the servo.

Step 2. Plug a 12" servo extension onto each servo. Tie a knot
at the connector as shown, then wrap with electrical tape to
prevent the servo connectors from pulling apart.

Step 3. Insert the servo into the aileron cutout in the bottom of
the wing as shown. Be sure the output shaft is oriented closest to
the trailing edge of the wing. Allow the servo lead to exit the root
of the wing. Refer to the photo in Step 4.

Step 4. Using the screws included with the servo, fasten the
servo in place. You may find it helpful to drill a 1/16

" pilot hole

before installing the screws.

Step 5. Remove the stock arms and replace with heavy-duty
1" arms (HAN3574 JR or HAN3575) to give the needed control
throws and to handle the increased loads of the large surfaces.
The arms need to face outward toward the wing tips as shown in
the photo. Be sure to use a drop of Blue Locktite to secure the
servo arm screws if using metal-geared servos.

Section 1: Installing the Aileron Servos

• Wings w/ailerons attached (taped in place)

Not Included

• (2) servos w/mounting hardware
(80 oz/in minimum torque)

• (2) 12" servo extensions

Included in Optional Hangar 9 Hardware Package
(HAN1220 JR or HAN1221 Futaba)

• (2) 1" Servo Arms (HAN3574 JR or HAN3575 Futaba)

• Phillips screwdriver

• Drill with 1/16" drill bit

• Electrical tape

• Blue Locktite

®

Parts Needed Tools and Adhesives Needed

Wing Tip

Trailing Edge

7

Step 1. Using a straight edge held in alignment (90°) with the
servo arm and with the hinge line as shown, mark the aileron with
a pen where the straight edge intersects the aileron hinge bevel.

Step 2. Measure exactly

1

/4

" rearward from the mark above
parallel to the hinge line and make another mark using a pen.
This will be the position for the control horn.

Step 3. Untape the ailerons from the wing. Use rubbing alcohol
to remove any tape residue. Notice that the hinge pockets are
already cut into place.

Step 4. Using a

5

/32

" drill bit and hand drill, carefully drill a

5

/32

" hole through the aileron at the marked position. [Drill
perpendicular (90°) to the aileron cross section rather than the
ailerons surface.] Be especially careful when penetrating through
the bottom surface of the aileron as it’s easy to split out the wood
and rip the covering. Placing a wooden block under the aileron
and drilling slowly will prevent these problems. If you choose to
use the counter sink screws included in the Hangar 9 Hardware
Package, counter sink the top of the aileron to allow the screws
to fit flush.

Note: A hardwood block (hardpoint) is located below the

sheeting; you will be drilling through this.

Section 2: Installing the Aileron Control Horns

• Wings with ailerons and servos

Included in Optional Hangar 9 Hardware Package

• (2) Control Horns (Rocket City 8-32 Swivel Control
Horn #ROC01B)

• 12" or longer ruler

• Drill w/ 5/32" drill bit

• 8-32 Tap (DUB363)

• 30-minute epoxy

• Pen

• Rubbing alcohol

• Paper towels

Parts Needed Tools and Adhesives Needed

Hinge Pockets

90°

8

Step 5. Using an 8-32 tap, tap the hole that you just drilled in
the aileron.

Step 6. Mix a small amount of 30-minute epoxy and lightly coat
the inside of the tapped hole and the 8-32 x 2" Rocket City screw.
From the top of the aileron, screw the 8-32 x 2" into the tapped
hole and securely tighten. Wipe away any excess epoxy with
rubbing alcohol and a paper towel. Screw the A-nut in place as
shown. Allow the epoxy to fully cure.

Step 7. Screw the molded swivel link onto the 8-32 screw until
the distance from the aileron surface to the bottom of the link
is

5

/8".

Step 8. Install the control horn in the opposite aileron using the
same method.

Section 2: Installing the Aileron Control Horns

CONTINUED

9

Properly hinging the control surfaces on giant-scale models is
vitally important! Poorly installed hinges affect the model’s
precision and control response and can also be dangerous. Each
and every hinge needs to be securely bonded in place in both the
flying surface and the control surface. The hinge pivot points
need to be exactly parallel to each other and precisely located on
the center of the hinge line. We regularly use Robart Super Hinge
Points in all giant-scale aircraft. They are easy to install, very
strong, and offer smooth friction-free control. The Hangar 9
Extra 330L control surfaces are predrilled to use Robart’s Super
Hinge Points.

Step 1. Sand each end of the hinge point hinge using coarse
sandpaper. This will improve the bond of the epoxy to the hinge.

Step 2. Mix 1 ounce of 30-minute epoxy. Using a glue syringe
or toothpick, place a sufficient amount of 30-minute epoxy into
one of the hinge pockets on the wings trailing edge. Install one
of the hinge points until the hinge pin center is flush with the
trailing edge of the wing. Some epoxy should ooze out of the
pocket as the hinge is installed. If not, remove the hinge and
apply more epoxy. After gluing a few hinges, you’ll get the hang
of just how much epoxy is needed. Wipe away any excess epoxy
with rubbing alcohol. Recheck that the center of the hinge pin is

flush and parallel with the trailing edge. Continue installing
hinges in the trailing edge of the wing. The control surfaces
(ailerons) will be installed after the epoxy is fully cured.

Note: Be sure that the hinge pivot pins are parallel and

flush to the trailing edge. It’s important to frequently
mix a fresh batch of 30-minute epoxy in order to
achieve good glue joint penetration. If you notice the
epoxy becoming thicker, then mix a new batch!

Section 3: Hinging and Sealing the Control Surfaces

• Wings with ailerons

Included in optional Hangar 9 Hardware Package

• (24) Robart Super Hinge Points #ROB309

Not included

• White UltraCote®(GBG870)

• Pearl Blue UltraCote®(GBG845)

• Sealing iron

• Sharp #11 hobby knife

• Ruler, 36"

• Glue Syringe (DLR910) (or toothpick)

• Coarse sandpaper

• Pen

• 30-minute epoxy

• Rubbing alcohol

• Paper towels

Parts Needed Tools and Adhesives Needed

10

Step 3. Allow the epoxy to fully cure for at least 6 hours. When
cured, work each hinge throughout its full motion several times
using your hands. This will break free any epoxy that may have
found its way into the hinge joint. Move the hinge throughout its
full travel until no resistance is felt. This may take as many as
40 or 50 times.

Step 4. Mix 1 ounce of 30-minute epoxy. Using a syringe or
toothpick, place a sufficient amount of epoxy in each of the hinge
pockets in one aileron half.

Step 5. Carefully install the aileron on the wing, making sure
the hinges are inserted in their respective hinge pockets. Press
the aileron and wing together such that less than a

1

/64" hinge
line gap exists between the aileron and wing. The bevels should
virtually touch. Using a paper towel and rubbing alcohol, wipe
away any visible epoxy around the hinges.

Step 6. Double-check the hinge gap and allow the epoxy to
fully cure for at least 6 hours. Now is a good time to epoxy the
hinges on the other aileron half using the same techniques.

Step 7. When fully cured, move each control surface
throughout its travel range several times to break away any epoxy
in the hinge. Be sure to deflect the surface fully.

Section 3: Hinging and Sealing the Control Surfaces

CONTINUED

11

Sealing the Hinge Gaps

It’s imperative that the aileron and elevator hinge lines be sealed
airtight to prevent flutter. Sealing the hinge line has several
advantages. A sealed hinge line gives a greater control response
for a given control deflection. It also offers more precise,
consistent control response and makes trimming easier.

Sealing the aileron and elevator hinge line is
mandatory. Failure to do so may cause control surface
flutter, resulting in a crash.

Step 1. Cut a piece of Pearl Blue UltraCote®(not included)

for sealing the ailerons to approximately 3" x 42". Fold the
UltraCote®down the center with the adhesive side to the outside
making a sharp crease at the fold.

Step 2. Using a ruler, measure 1/2

" from the folded crease and

mark two places with a pen.

Step 3. Using a sharp #11 blade and a straight edge, carefully
cut through both layers of UltraCote

®

covering at the 1/2" point

marked in Step 2.

Step 4. Mark and cut the folded covering to an overall length
of 40". This piece will be inserted and ironed down into the hinge
bevel on the bottom of the aileron.

Section 3: Hinging and Sealing the Control Surfaces

CONTINUED

12

Sealing the Hinge Gaps(CONTINUED)

Step 5. Remove the backing from the UltraCote®. Place the

folded crease side into the center of the hinge line on the bottom
of the wing. Using a straight edge as shown, hold one side of the
covering in place while ironing down the opposite side with a
sealing iron. We recommend setting the iron temperature to
320°for this operation.

Step 6. Fully deflect the aileron in the up position. Place the
straight edge over the hinge line covering that you just ironed
down in Step 5 with the edge of the straight edge placed firmly at
the bottom of the hinge line as shown. Iron down this side of the
covering, making sure the aileron is fully deflected.

Section 3: Hinging and Sealing the Control Surfaces

CONTINUED