Hobbico Extra 300 Assembly Instructions/use And Care Manual
ALMOST READY-TO-FLY RADIO CONTROLLED MODEL AIRPLANE
• SUPERIOR QUALITY IN AN ALMOST-READY-TO-FLY MODEL.
• SPECIAL COVERING PROCESS YIELDS A STRONG, BRILLANT, AND FUEL-PROOF
FINISH.
• 80% COMPLETE OUT OF THE BOX - NO SANDING, PAINTING, OR FINISHING REQUIRED
• WORLD CLASS AEROBATIC CAPABILITIES, JUST LIKE THE REAL EXTRA 300.
• BEAUTIFUL SEMI SCALE APPERANCE.
WINGSPAN: 553/4"
LENGTH: 44 1/2"
WING AREA: 543sq.in.
WEIGHT: 91-95 oz.
RADIO: 4-Channel (Not Included)
ENGINE: .46 Performance 2-Cycle (Not Included)
or 60-70 4-Cycle (Not Included)
ACCESSORIES: Starting Battery w/Clip, Fuel Etc. (Not Included)
ENTIRE CONTENTS © 1990, V1.0 INC.
IMPORTANT: BEFORE YOU BEGIN.
Congratulations on your choice of an ASAP kit. BEFORE you begin assembly, carefully look through the box and
thoroughly read the instruction manual. Also check the parts list against the items in the box to be sure you have
everything that is on the parts list. Also check the parts list against the items in the box to be sure you have everything
that is on the parts list. Although we have taken great pains to simplify the building process, there are no shortcuts
to safety. These instructions are your guide to safe and successful flying.
Only after you are thoroughly familiar with the construction process should you proceed with assembly.
Remember! Under no circumstances will a dealer accept a kit back for return if assembly has already begun.
If the Extra 300 is not quite what you expected, return it to your dealer in New and Unused condition. However,
we think you will agree with us that the Extra 300 kit is one of the finest models of its type and will offer you many hours
of enjoyment.
BEFORE ASSEMBLY
CONSTRUCTION HINTS:
1. Trial fit each part before gluing. Be certain that the parts fit properly.
2. Use PlastiZap or a thin type Cyanoacrylate glue for installing the
plastic parts. Do not use too much, as it may run and spoil the
appearance. Do not get Cyanoacrylate on the foam parts of the Extra
300. Cyanoacrylate will destroy the foam.
3. It is best to use 30 minute epoxy where required. This allows time
to position the parts before the epoxy cures.
4. Before assembly, place your radio system on charge.
5. There is a metric ruler on page 3 to aid in finding the correct screw
sizes.
ADDITIONAL
ITEMS
The following items are needed for completing the Extra 300 kit:
Medium Fuel
Tubing
(12")...................................................................
1
.46 Sized 2-Cycle
Engine....................................................................
1
OR
.60 - .70 Sized 4-Cycle
Engine............................................................
1
4-Channel Radio System
....................................................................
1
Pacer
PlastiZap CA Glue
....................................................................
1
Goldberg #481
Foam
Rubber
....................................................................1
Hobbico (HCAR3950) 30-Minute
Epoxy..............................................
1
Silicone
Sealer....................................................................................
1
Dubro
121
E-Z
Connects
(Optional)
....................................................2
Dubro
203 Kwik-Switch Mount
(Optional)............................................
1
Hobbico (HCAR3760)
Threadlock.......................................................
1
Dubro In
Line
Fuel
Filter......................................................................
1
TOOLS REQUIRED
TOOLS-
You will need the following tools to assemble the Extra 300: X-Acto knife,
Philips screwdriver (small and medium), needle nose pliers, drill, drill bits,
sand paper, ruler, and string.
2-
Most engines require a 1.5V glow plug starting battery, a glow plug clip,
and a quality brand fuel (consult the engine manufacturer's
recommendatiions).
A quality brand engine will be needed. We recommend the O.S. .46 SF
2-cycle engine or the O.S. 70 Surpass 4-cycle. A prop and fuel tubing will
be required for the engine.
A four-channel radio control sytem with 4 servos is required for the Extra
300. The various components are pictured above.
PARTS LIST
Before assembly, match the parts
in the exploded view of the Extra
300 with the parts in the kit. Check
off each part on the parts list. If any
parts are missing or damaged
return the kit to your hobby dealer.
Check to make sure that all the
listed parts are included in your kit.
1 Fuselage
2 Right Wing
3 Left Wing
4 Wing Center Cover (Plastic)
5 Vertical Fin
6 Rudder
7 Horizontal Stabilizer
8 Cowl (4 Piece)
9 Fuel Tank
10 NeopreneRing
11 Plastic Disc (Small)
12 Plastic Disc (Large)
13 Silicone Tubing
14 Clunk
15 3x18mm Self-Tapping Screw
16 Rubber Plug
17 Plastic Collar
Aileron Horn
Control Horns
Snap Clevis
Rod Clevis
Back Plates
18 Fuel Pipe
19 Mounting Plates (Angled)
20 Clevis Retaining Tube
21 Push Rod Exits
22 Stab. Root Cover (Plastic)
23 Wheels
24 Main Gear
25 Wheel Pants
26 Cock Pit
27 Canopy
28 Main Wing Joiners
29 Rear Wing Joiner
30 Front Wing Joiner
31 Rubber Shock Absorber
32 Cowl Brace
33 Aileron Servo Tray Mount
34 Aileron Servo Tray
35 8mm Dowel Rod
36 Wing Bolt Mounting Block
37 Balsa Tank Support
38 Wing Mounting Brace
39 3x12mm Self Tapping Screw
2 1/4" Spinner
Spinner Back Plate
40 Engine Mount
41 Mounting Plates
42 Shrink Tubing
43 Control Rod (Short-Bent)
44 Control Rods
45 Throttle Control Rod (Long)
46 Throttle Tube
47 Wood Push Rods
48 Plastic Disc (Red)
49 Main Servo Tray
50 Stabilizer Supports
51 Plastic Disc (Blue)
52 CockPit Mounts
53 Brass Sleeve
54 Brass Tube
55 Tail Wheel
56 Tail Gear
57 Tail Gear Mount
58 1/8" Wooden Wedge
59 0-Ring
60 Collars
61 Wheel Collar
62 4 x 40mm Screw
63 4 x 30mm Screw
64 2x15mm Screws
65 3 x 8mm Self-Tapping Screw
66 3 x 8mm Screw
67 3x12mm Self-Tapping Screw
68 3 x 5mm Screw
69 3.5 x 15mm Screw
70 3x12mm Screw
71 4x15mm Screw
72 4 x 20mm Screw
73 4mm Nut
74 2mm Nut
75
3mm Nut
76 4mm Washer
77 3mm Washer
78 2mm Washer
79 Lock Washers
80 4mm Washer
81 4mm Nylon Nut
82 Cowl Stripes (Red)
83 Decal Sheet
-3-
WING ASSEMBLY
A.
Right Wing
(Aileron
Installed) ..........1
B. Left Wing (Aileron Installed)......... 1
C. Main Wing
Joiner.........................
2
D. Rear Wing
Joiner.........................
1
E.
Front Wing
Joiner........................ 1
F Wing Center Cover (Plastic)........ 1
G. 8mm Dowel Rods
..........................2
H. Wing
Bolt
Mounting
Block.............
1
I. Wing Mounting Brace.................. 1
J. 4 x
30mm
Bolts
...........................2
K. 4mm Washer
...............................2
L
0-Ring
........................................2
M. Aileron Servo Tray
......................1
N. Aileron Servo Tray Mount............ 1
0.
Main
Swvo
Tray..........................
1
3. Remove the foam covering from the aileron servo mounting area
from the top side of the wing. Test fit the main wing joiner and the
rear wing joiner in the right and
left
wing
sections.
The dihedral angle
of the joiners should make the wing tips slightly higher than the
center.
4. Make sure that there is no gap between the wing halves. If there is,
sand the wing joiner ends until there is a tight fit.
1. Align and epoxy the two main wing joiners together. Hold tight until
the glue sets. You'll notice that there is dihedral angle cut into the
joiners so make sure they are perfectly lined up.
2. Check each wing half for smooth aileron operation. It is a good idea
to exercise (move back and forth) the ailerons to insure easy
deflection. Trim the end of the aileron if any rubbing is noticed.
-4-
5. Apply epoxy to one half of one side of both the main and rear wing
joiners and glue them to one wing half. Make absolutely sure the
wing joiner pocket is well coated with epoxy. Make sure the
dihedral angle is correct and that the wing halves are slid in all the
way. Clean any excess epoxy with paper towel and isopropyi
alcohol.
6. After the joiners have cured, apply epoxy where shown. The wing
roots, the wing joiners should be evenly and liberally covered with
epoxy. The wing joiner pocket should be heavily coated with epoxy.
9. Drill two 8mm (5/16") holes into the wing joiners for the dowel
rods. Drill through the front joiner and into the rear wing joiner.
7. Slide the two wing halves together slowly and wipe off any excess
glue. With the wing on a flat surface, hold one wing half down so the
other end will be elevated. The wing tip should be 1 1/16" off of
the surface. Hold the two wing halves firmly together with tape until
the epoxy has cured.
10. Epoxy the two dowel rods into the holes. Make sure they pass all the
way through the front joiner plate and are inserted into the rear
joiner.
8. Once cured, remove the tape. Position the front joiner as shown.
The flat edge of the joiner should line up with the top of the wing.
Next, remove and epoxy in that same position. Let cure. NOTE: You
may have to trim the covering for a tight wood to wood joint. This is
very important to the structural integrity of the wing.
11. Position the wing center cover on the bottom of the wing. Apply
Cyanoacrylate glue (PlastiZap) under the edges and hold until it
sets.
-5-
12. Epoxy in the main servo tray as shown.
15. Screw in the wing bolts into the wing bolt mounting block so that the
heads are 1/4" above the block. Apply ink or paint to the heads of
the two bolts.
13. Test fit the wing bolt mounting block to the inside of the fuselage. The
blind nuts should face down. Make sure that the blind nuts are
securly pressed in and then place a drop or two of Cyanoacrylate to
hold them in. Make sure that no glue gets on the threads
16. After the epoxy has cured, place the wing into the fuselage as shown.
Put the front in first by inserting the dowel rods in the holes. Once
in place lower the back into position. This will mark where you need
to
drill.
14.
Epoxy in the wing bolt mounting block. This is a high stress point and
extra care should be taken to ensure a strong joint. Let cure.
17. Place the wing mounting brace onto the wing as shown and center
the wing and brace in the fuselage. NOTE: The two indentations on
the brace should face up. Trim away any wood to allow the aileron
torque rods to move freely. Use PlastiZap to glue this in place.
-6-
LANDING GEAR INSTALLATION
18. Drill two 4mm holes 90' from the top wing surface for the wing bolts
where the paint marks are.
19. Assemble the wing bolts as shown (Bolt - Washer - Wing - 0-ring)
and temporarily fasten down the wing. Check for a good fit and
then remove.
20. Trial fit the aileron servo tray mount and tray to the wing. NOTE: The
front edge should be on the wood. You will have to trim away a little
covering to insure a good fit. You may also have to trim the bottom
of the servo tray mount so it will fit flush inside the wing. Epoxy the
aileron servo tray mount into the rear section of the wing servo mount
and then epoxy in the tray.
A. MainGear.................................. 1 H Wheel Pants...............................2
B.
Rubber
Shock
Absorber..............
1 I. 4mm x 40mm Screw
...................2
C 4mm x 30mm Screw
....................2
J.
3mm x 12mm Screw
...................2
D. 4mm Washer.............................4 K.
3mm Washer.............................2
E. 4mm
Nut...
.................................6
L
3mm
Nut.
................................2
F. 4mm
Nylon
Nut............................ 2 M.
Plastic
Spacer................................
2
G.
Wheel............................................ 2
1. Drill two 4mm holes at the indents.
2. Remove the wing. Place the two 4mm x 30mm screws with the
4mm washers into the two landing gear holes that are located inside
the front fuselage section.
3. Thread two 4mm nuts onto the two screws and tighten Next place
the rubber shock absorber over the screws.
6. Arrange the above parts as shown and then assemble together. Do
this
twice. Place
thread lock on the
threads when
installing
the
nuts
4. Now place the main gear over the screws and secure it with two 4mm
nylon nuts NOTE: tighten
both one turn. This will give the gear the correct shock absorbing
qualities.
5. Next, take the two wheel pants and drill two holes in each one The
first hole should be at the indent (4mm in diameter) The second
should be 3/8" above the first and smaller (3mm diameter) Apply
the wheel pant's decal stripes to both sides of the two wheel pants.
the nuts
all
the way and then loosen them
7. Place the 3mm screw/washer into the top hole of the wheel pants
from the inside And then attach it to the top hole of the main gear
using a 3mm nut with threadlock.
8. Flare open the pants and insert the wheel assembly Install the 4mm
nut with threadlock and tighten, holding the inside nut with needle
nose pliers.
-8-
9. Make sure that both wheels rotate freely. If they do not, trim away
the plastic as needed. Or if need be, loosen the nuts and reposition
the wheel.
2. Install the two mounting plates onto the engine mount. Next, paint
a strip on each plate using four 4mm x 15mm screws and washers
and proceed with the following step before the paint dries.
ENGINE INSTALLATION
FOLLOW THE SAME PROCEDURE FOR EITHER 2-CYCLE OR 4CYCLE INSTALLATION.
A.
Engine
Mount..............................................................................
1
B. 4mm x 20mm
Screws
.................................................................4
C.
Mounting
Plates
..........................................................................
2
D. 4mm x 15mm Screws
.................................................................4
E.
4mm
Washers.............................................................................
4
F.
Lock Washers
.............................................................................8
G.
3.5mm Screw
..............................................................................4
H. 3.5mm
Nuts
................................................................................4
3. Before touching the plates, align the engine so it is pointing straight
forward. Center the engine with the plates and carefully touch the
engine into position. Now carefully remove the engine and there
will be the guides for drilling the mounting holes.
1. Install the engine mount to the fuselage using four 4mm x 20mm
screws and four lock washers. Note the direction the mount is
installed for proper engine positioning. Also use threadlock on the
screw threads.
-9-
4. Drill two 4mm holes in each mounting plate at the marks.
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