AeroWorks Extra 300 ARF-QB Assembly Manual

1

100cc Extra 300 ARF-QB

(Quick Build)

ASSEMBLY MANUAL

AEROWORKS

4903 Nome St– Denver, CO. 80239

www.aero-works.net

2

TABLE OF CONTENTS

Page

Aeroworks Contact Information …………………………………………………………………………. 3

Introduction / Warranty…………………………………………………………………………. ………. 4

Kit Contents………………………………………………………………………………………………… 5

Items Needed To Complete ……………………………………………………………………………….. 8

Tightening and Re-shrinking The Covering ……………………………………………………………… 9

Checking Seams and Color Overlaps for Good Seal / Sealing Hinge Gaps ………..………………….. 10

Wing Assembly………………………………………………………………….…………………………. 11

Stab and Elevator Assembly………………………………………………………………………………. 17

Rudder and Rudder Servos Installation ………………………………………………………. ……….. 20

Tail Wheel Installation ………………………………………………………………………….. ………. 29

Main Landing Gear, Gear Cuffs, and Wheel Pant Installation ….………………………….. ……….. 32

Engine Installation ……………..…………………………………………………………………………. 37

Throttle and Choke Servo Installation …………………………………………………………………… 39

Ignition Installation . …………………………..…………………………………………………………. 44

Fuel Tank Assembly and Installation …………………….……………………………………. ………. 47

Standard Muffler/Cowl Installation ……………………..……..………………………………. ………. 53

Canister Muffler/Cowl Installation ……………………………………………………………. ………. 57

Tuned Pipe/Cowl Installation ………………………………..…………………..…………….. ………. 60

Radio Installation …………………………………………………………………………………………. 63

Preflight Preparation ………………………………………………………………………...….. …….. .. 66

Decal installation ………………………………………………………………………………………… 68

Center of Gravity / Control Throws ……………………………………………………………. ……… 72

Control Deflection Table ………………………….………………………………………………………. 75

Preflight Check List ……………………………………………………………………………………… 76

3

4903 Nome Street

Denver, CO 80239

Phone: (303) 371-4222

Fax: (303) 371-4320

Website: www.aero-works.net

E-mail: [email protected]

Thank you for choosing the Aeroworks 100cc Extra 300 ARF-QB. We put great effort

into making this plane the best model you will ever build and fly. We have provided you

with the highest quality kit and performance possible. We wish you great success in the

assembly and flying of your new Aeroworks 100cc Extra 300 ARF-QB.

!WARNING!

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and property

damage. Fly only in open areas, and AMA (Academy of Model Aeronautics) approved

flying sites. Follow all instructions included with your plane, radio, and engine.

Aeroworks manufacturing guarantees this kit to be free from defects in both material

and workmanship at the date of purchase. This limited warranty does not cover any

component parts damaged by use or modification. In no case shall Aeroworks liability

exceed the original cost of the purchased kit. Further, Aeroworks reserves the right to

change or modify this limited warranty without notice.

In that Aeroworks has no control over the final assembly or materials used for final as-

sembly, No liability shall be assumed nor accepted for any damage resulting from the

use by the user of the final user-assembled product. By the act of using the user-

assembled product, the user accepts all resulting liability.

We, as the kit manufacturer, have provided you with a top quality, thoroughly tested kit

and instructions, but ultimately the quality and fly ability of your finished model

depends on how you build it; therefore, we cannot in any way guarantee the

performance of your completed model, and no representations are expressed or

implied as to the performance or safety of your completed model.

4

INTRODUCTION

Your new 100cc Extra 300

ARF-QB is a highly aerobatic airplane. It is capable of both

precision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its

state of the art CAD design, LASER cut technology, and high quality included hardware.

We hope you enjoy building and flying your 100cc Extra 300 ARF-QB.

Great care has been taken in both the design and manufacturing of the 100cc Extra 300

ARF QB to allow for the strongest and lightest construction possible. Only the highest qual-

ity materials from the covering, paint, wood and hardware have been used in the construction

of this model.

The 100cc Extra 300 ARF-QB has been individually hand built, covered and painted by

trained and experienced craftsmen with over 25 years of manufacturing experience. Using

CAD design, laser cut technology and jig-built assures accuracy in all stages of production.

The 100cc Extra 300 ARF-QB is designed for gas engines in the 100cc category. The DA-

100cc engine is shown in the assembly instructions. The aircraft was tested with the DA-

100cc and has outstanding performance. The final choice of engine is left up to the builder.

A computer radio is recommended to allow the pilot to take advantage of the full capabilities

of this aerobatic aircraft.

IMPORTANT Please read through this assembly manual carefully, before starting the as-

sembly of your new model. Inventory and inspect all parts and hardware for any imperfec-

tions or damage. Notify Aeroworks immediately if there are missing or damaged parts

and do not proceed with the assembly. Inspect all parts and hardware prior to any assembly,

failure to do so could void any warranty coverage.

INTENDED USE

This plane should not be regarded as a toy. This is an aerobatic plane and is recommended for pilots

who are beyond the trainer-stage and are comfortable with flying an aerobatic sport plane.

READ! LIMITED WARRANTY READ!

It is important to notify Aeroworks of any damage or problems with the model within 30

days of receiving your airplane to be covered under warranty. If you wish to return this air-

craft for any reason a 15% restock fee will be charged to the customer. In addition the cus-

tomer is responsible for all return shipping cost and all prior shipping cost will not be re-

funded. Parts will be exchanged or replaced once the original item is returned at the owner’s

expense. If you have any problems or questions, please contact Aeroworks.

Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the

construction or use of this aircraft, and therefore, will not be accountable for any property

damage, bodily injury or death caused by this aircraft.

Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the

construction or use of this aircraft, and therefore,

The purchaser/operator accepts all responsibility of any and all structural or

mechanical failures.

5

KIT CONTENTS

100cc Extra 300 ARF-QB

Basic Aircraft Parts:

Fuselage with pre-installed vertical fin , firewall fuel-

proofed, tail wheel assembly holes pre-drilled

(4) 8-32 blind nuts installed for main landing gear

(4) 4-40 blind nuts installed for the mounting of the

stab.

(2) 4-40 blind nuts installed for the mounting of

cowling.

(1) Top hatch cover of engine box with AW logo

installed by (4) T2.6x10mm PWA screws

(1) Landing Gear hatch cover installed by (2)

T2.6x16mm PWA screws

(2) Exit Slot Covers – covered and installed on the

bottom of the fuselage by (8) T2.6x10mm PWA

screws

(2) Aluminum L Barackets, 1 left and 1 right in-

stalled by M4x15mm bolts and M4 locks and

4mm flat washers

Canopy base—painted, with (4) 4-40 blind nuts

installed

(1) Tinted Canopy—glued on the canopy base and

painted,

(4) #6 bonded washers for the mounting of the can-

opy

(4) 3mm split lock washers for the mounting of the

canopy

(1) 3.5(o.d.) x1250mm Antenna tube installed

(2) 3.5(o.d.) x120mm pull-pull exit tube installed

(1) Pre installed – Long Pipe mounting brackets

with 60mm dia. holes

(1) Pre installed – Canister mounting bracket with

70mm dia. holes

Left Wing with Aileron – covered: Pre-drilled for the

mounting of the control horns

(2) 8-32 blind nuts installed for the wing mounting.

(2) located pins installed pre-drilled holes for cotter

pins.

(8) pin point hinges glued

(2) Aileron servo string installed

Right Wing with Aileron – covered: Pre-drilled for the

mounting of the control horns

(2) 8-32 blind nuts installed for the wing mounting.

(2) located pins glued pre-drilled hole for cotter pin

(8) pin point hinges installed

(2) Aileron servo string installed

6

Horizontal Stabilizer with elevator assembly with (12)

pin point hinges (glued)---covered

Elevators Pre-drilled for the mounting of the

control horns

Rudder with (7) pin point hinges (not glued) – covered

Rudder Pre-drilled for the mounting of the con-

trol horns and 2 holes for rudder tiller arm

SUB ASSEMBLIES:

#1:

(1) Fiberglass Cowling—painted with (2) screws holes

and (2) 6-32 blind nuts installed

(2) 4-40x16mm hex style bolts for mounting cowling

(2) #6 bonded washers for mounting cowling

(2) 3mm split lock washers for mounting cowling.

(2) 6-32x15mm hex head bolts for mounting cowling

(2) #6 bonded washers for mounting cowling

#2:

(1) 5mm 7075Aluminum Main Landing Gear – painted

white

(2) 5x48mm Axle Bolts

(2) M8 lock nuts

(4) 5mm i.d. Wheel Collars with set-screws

(2) 110mm Dia. Main Wheels (Lite Type)

(4) 4-40x16mm hex style bolts for mounting wheel

pants

(4) 3mm flat washer for mounting wheel pants

(4) 3mm split ring lock washer for mounting wheel

pants

(4) 8-32x25mm hex head bolts for mounting main land-

ing gear

(4) 4mm flat washers for mounting main landing gear

(4) 4mm split ring lock washers for mounting main

landing gear.

#3:

(2) Wheel Pants—1 Left and 1 Right---Painted

(4) 4-40 blind nuts installed on the wheel pants, 2 per

side.

#4:

(2) Landing Gear Cuffs, 1 left, 1 right, Marked with L

and R; painted

(4) 4-40x7mm hex style bolts for cuffs mounting

(4) 3mm flat washers for cuffs mounting

#5:

(1) Tail Wheel Assembly – Large

#6:

(1) 40mm o.d. Anodized Aluminum Tube for wing joint

(2) 12.5mm o.d. Anodized Aluminum for stab joint –

one front and one rear

(4) 8-32x25mm Hex head bolts for wing mounting

(4) #8 bonded washers for wing mounting

(4) 4mm split ring lock washers for wing mounting

(4) 4-40x16mm Hex style head bolts for stab mounting

(4) #6 bonded washer for stab mounting

(4) 3mm split ring lock washer for stab mounting

(4) 1.8mm cotter pins-wing retainer

#7:

(2) 4-40 2-1/2”” left hand and right hand threaded

pushrod with nuts and carbon tubes for elevators

(4) 4-40 3” left hand and right hand threaded pushrod

with nuts and carbon tubes for ailerons

(1) Wrench for the left hand and right hand threaded

pushrod

(2) 4-40x300mm Threaded pushrod

(2) 4-40 solder coupler with nuts

(2) 4-40 Metal clevises

(8) Brass spacers – 4 for ailerons; 2 for elevators; 1

for throttle; 1 for choke

(14) 4-40 Ball Link – 8 for ailerons; 4 for elevators; 1

for throttle; 1 for choke

(14) 4-40x16mm hex style bolts

(14) 4-40 lock nuts

(8)Φ3 flat washers

#8:

(2) 1x1300mm plastic coated pull-pull steel cable.

(4) 4-40 Metal R/C links with nuts

(4) 3.5x5mm brass pull-pull swaging tubes

(8) AW double control horns

(48) T2.6x16mm Phillips head mounting screws

(2) 4-40x36mm left hand and right hand threaded

push rod for connecting rudder servo

(4) 4-40 Ball Links for connecting rudder servo

(2) 4-40x16mm hex head bolts for connecting rudder

servo

(2) 4-40x20mm hex head bolts for connecting rudder

servo

(4) Brass Spacers for connecting rudder servo

(4) 3mm flat washers for connecting rudder servo

(4) 4-40 Ball Links – Rudder

(4) 4-40 x16mm hex style bolts

(4) 4-40 lock nuts

(2) Brass Spacers for rudder

(2)Φ3 flat washers

#9:

(1) 1000cc gas tank

(1)750cc gas tank – smoke tank

(1) 4ft. large gas fuel line

(4) Brass barbs for fuel line

#10:

(4) Wooden servo mounting tray for throttle and

choke servos

7

(3) Engine mounting template (3W, DA and Univer-

sal)

(1) Front Cover for the exit hole of the front exit style

canisters

(24) 11 dia. x 24mm silicon tubes

(1) 160x100x6mm foam for the fuel tank.

(1)160x70x6mm foam for the smoke tank

(3) 300x80x8mm sponge for the receiver and battery

(8) 4.5x500mm Nylon ties

(10) 3x150mm Nylon ties

(6) 12.5x356mm Velcro

(6) Rubber grommets – fuel line and wire guide

(1) 300x300 White

(1) 300x300 True Red

(1) 300x300mm Black

(2) 20x1780mm transparent covering – Sealing hinge

gaps

#11:

(24) 6mm aluminum engine stand offs.

#12:

(1) Customer Throw Meter

(1) Paper Degree Meter for Rudder

#13:

(1) Custom – Vinyl Decal Set

-Decal set supplied with kit may very from pic-

tures. Optional decal set available from

Aeroworks.

#14:

(1) Assembly Manual with picture folders on CD

8

Hardware:

ITEMS NEEDED TO COMPLETE

• 100cc gas engine with ignition, mufflers or

headers, with canisters or pipes, and all engine

mounting bolts, lock nuts, and washers.

• 4” Spinner and propeller of your choice

• 4 x aileron servos (min. 180 in./oz. Digital,

Metal Gear)

• 2 x rudder servos (min. 180 in./oz each or 300

in./oz. total torque, Digital, Metal Gear)

• 2 x elevator servos (min. 180 in./oz. Digital,

Metal Gear)

• 1 x throttle servo (fast / reliable)

• 1 x choke servo (fast / reliable) (Optional)

• Servo extensions - Heavy Duty - (22 gauge min)

3 x 11” Y harness, 2 x 6,” 2 x 12”, 2 x 24”, 2 x

48”

• 1 Receiver (PCM recommended)

• 1 x Receiver battery (min 6.0 volt / 1700ma)

• 1 x Ignition battery (min 4.8 volt / 1700ma)

• 2 switches with charge jacks (22 Gauge min)

Tools:

• Allen wrenches US and Metric.

• Dremel cutting disc and sanding drum tool

• Electric drill and selection of bits

• Flat head screwdriver

• Hobby heat gun

•

Hobby iron with protective sock

•

Masking tape

• Modeling knife

• Needle nose pliers or crimping tool

• Paper towels

•

Pen, pencil or felt tipped marker

•

Phillips screwdriver

• Ruler and tape measure

• Scissors

• T pins

• Waxed paper

• Wire Cutters

Adhesives:

•

15-30 Minute epoxy

•

Blue Loctite (Thread Locker)

• Epoxy mixing cups, sticks, brushes

•

CA kicker (optional)

• Thick and Thin CA

• Rubbing alcohol

• Wipes

!WARRING!

Some rubbing alcohols

may attack painted parts.

9

1. Open your kit slowly and take care not to dam-

age any parts of the kit. Remove all parts from

their plastic protective covers for inspection.

Before doing any assembly or installation of any

decals it is very important

to re-shrink or re-

tighten the already applied covering. Due to the

shipping process, heat and humidity changes

from different climates, the covering may be-

come lose and wrinkle in the sun. If you take the

time to re-tighten the covering, you will be re-

warded with a long lasting beautifully covered

model.

TIGHTENING AND RE-SHRINKING THE COVERING

2. Using your covering iron with a soft sock, gently

apply pressure and rub in the covering. If any

bubbles occur, your iron may be to hot. Reduce

heat and work slowly.

!IMPORTANT!

Go over any and all seams and color overlaps

with your iron to assure good adhesion of the

covering to the wood. This is especially im-

portant at the leading edges of the wings and

stabs.

3. If bubbles persist, use a small pin to punch holes

in the bubble to relieve trapped air and reheat.

4. Use your heat gun with extreme caution. Take

care not to apply too much heat to one area for

long periods of time. This may cause the trim

colors to over shrink and pull away leaving un-

sightly gaps on the color lines. The trim stripes

are especially vulnerable to over heating and

over shrinking.

5. Your model is covered with Ultracote™ cover-

ing. In case of repairs, the colors are:

True Red #866

White #870

Black #866

Silver #881

Tightening and re-shrinking the covering is now

complete

. However, this is a never ending

process and should be checked after each

flying session.

10

1. Go over all seams and color overlaps with your

sealing iron.

Note: Even if your models covering has no wrin-

kles out of the box it is still very important to

go over all seams and overlaps to make certain

they are sealed securely. This is especially

important at the leading edges of the wings and

stabs. We recommend checking the covering

after each flying session.

CHECKING SEAMS AND COLOR OVERLAPS FOR GOOD SEAL

SEALING HINGE GAPS

2. Use covering iron to ensure all edges, seams,

and color overlaps are securely sealed.

3. Sealing hinge gaps. This is an optional step

but is recommended.

Cut strips of the supplied clear covering to fit

the hinge gaps. Use covering iron to seal the

clear covering snugly into the bottom of the

hinge lines as shown for air tight hinge seals.

Note: The clear covering does have a transparent

protective backing. This must be removed

prior to applying heat and to the surface.

IMPORTANT:

It is the responsibility of the purchaser /

operator to check the covering seams and

overlaps for security and a good seal.

Aeroworks is not responsible for failure of

covering seams or overlaps during flight.

Note: If covering continues to lift apply a small

amount of thin CA underneath the covering.

Then using a clean rag apply pressure to secure.

One of the most important tools in your

flight box is a roll of clear tape. This can be

used at the field for fast and easy repairs of

the covering. Then once you have finished

flying the covering can be permanently

repaired.

11

Aileron Servo Installation

1. The ailerons have been pre-hinged and glued to

the wing panels and are ready for flight. No

other steps are necessary for hinging. Clear

Covering is supplied for sealing the hinge gaps if

desired. However, due to the precisely aligned

and minimal hinge gap this step is optional.

Gather one wing panel, two aileron servos, one 11”

Y harnesses, and one 24” servo extension as

shown below to begin the servo installation.

Note: A 6” extension will also be needed per wing

when connecting aileron servos to receiver.

WING ASSEMBLY

2. Layout the servos, extensions and Y harness on

the wing to test fit the installation and ensure

servo leads are the correct length.

Minimum recommended servo:

180 in. oz. / Metal Geared / Digital

3. Attach the 24” extension to the outboard servo

lead and secure with an Aeroworks safety clip.

Ensure the connectors will not come apart from

vibration or light tension.

IMPORTANT

1. If hinges will not go to the full deflection it may

be necessary to apply heat using a heat gun

while holding the surface at its full deflection.

This will allow the hinges to move freely.

12

5. Pull the servo lead through the root end of the

wing.

6. Attach the Y harness to the inboard servo

lead and secure with an Aeroworks safety

clip. Ensure the connectors will not come

apart from vibration or light tension.

7. Remove the balsa stick with the pull string from

the servo well and tie the pull string to the servo

lead as shown.

4. Remove the balsa stick with the pull string from

the servo well and tie the pull string to the servo

lead as shown.

13

9. Plug the male ends of the 24”extension into

the female ends of the Y harness. Next plug

the male end of this Y harness into the female

end of the other Y harness.

10. Secure all Y harness connections with safety

wire, string, tape, or other method. Ensure the

connectors will not come apart from vibration

or light tension. Secure excess wire from Y

harness and extensions inside the wing root rib

using tape or Velcro as desired.

11. Install servo in servo well with the output shaft

toward the leading edge of the wing. Use a

1/16 bit to drill servo mounting holes.

8. Pull Y harness through root end of wing.

14

13. Repeat mounting steps for other servo so that

aileron servos are mounted in bottom of wing

as shown.

Note: Servo output shaft should face towards the

wing leading edge. Servo arms should point

towards the wing tip.

Aileron Control Linkage Installation

1. Gather the aileron control linkage parts as shown

below. There are (2) 4-40 pushrods, (4) 4-40 ball

link assemblies, (2) Flat washers (2) brass spacers,

(2) left and (2) right side control horns, (1) Adjust-

ment wrench (4) carbon reinforcement sleeves and

(12) wood screws for each wing panel.

2. Assemble two pushrod and control horn

assemblies as shown. The ball link goes

between the left and right sides of the control horn

sides and is secured with a nylon lock nut.

IMPORTANT: The ball link for the root end

control horn goes in the bottom hole of the horn.

The ball link for the tip end

horn goes in the mid-

dle hole of the horn. This gives the correct offset

to eliminate binding and twisting of the aileron.

Note: It will still be necessary to either program or

use a after market type Match Box system to as-

sure your servos will not bind or fight against

each other.

Improperly installed servo linkages can cause ser-

vos to strip and ailerons to flutter. Aileron flutter

can and will destroy your model instantly!

Tip end

Middle hole

Root end

Bottom hole

12. Install servo with servo mounting screws.

15

4. Align the control horns over the factory drilled

holes.

Note: Control horns have been set at a slight

offset to allow for maximum torque at full

deflection

6. Align the left and right sides of the control horns

to the mounting holes and secure using six wood

screws as shown.

5. Use thick CA on each screw prior to

installing to lock screws in place

Note: CA glues have a fast drying time.

Remember to work quickly

3. Correct installation of ball link, flat washer and

brass spacer to servo arm shown below.

Note: Flat washer prevents ball link from

coming off brass ball.

16

8. Plug the servos into the receiver and turn on.

Ensure servos are centered and the servo arms

are parallel to the aileron hinge line. Adjust

the length of the pushrods so that the aileron is

at the neutral position when the servo arms are

parallel to the aileron hinge line. Ensure all

servos do not fight each other at center or

either end point at full deflection. Take advan-

tage of servo programmers and match boxes

available today to achieve best results. This

will help keep servos from binding and

causing possible aileron flutter.

7. Install servo arm to pushrod as shown below.

17

Elevator Servo Installation

1. The elevators have been pre-hinged and glued to

the stabs and are ready for flight. No other steps

are necessary for hinging. Clear covering has

been provided for sealing of the hinge gaps if

desired.

Gather the stab and elevator, one elevator

servo, and one 48” servo extension.

Note: 48” servo extension will be used to

connect servos to receiver during a later

step.

STAB AND ELEVATOR ASSEMBLY

2. Install servo in servo well with the output shaft

toward the leading edge of the stab. Fish the

servo lead through the stab and out of the stab

root rib.

3. Mark locations of servo mounting holes. Use a

1/16 bit to drill servo mounting holes.

4. Install servo with servo mounting screws.

1. Gather the elevator control linkage parts as

shown below. There are (1) 4-40 pushrods, (2)

4-40 ball link assemblies, (1) Flat washers (1)

brass spacer, (1) left and (1) right side control

horns, (1) Adjustment wrench (2) carbon rein-

forcement sleeves and (6) wood screws for each

elevator half.

Elevator Control Linkage Installation

18

4. Align the control horns over the factory drilled

holes.

Note: Control horns have been set at a slight

offset to allow for maximum torque at full

deflection

5. Use thick CA on each screw prior to installing

to lock screws in place

Note: CA glues have a fast drying time.

Remember to work quickly.

2. Assemble the pushrod and control horn assem-

bly as shown. The ball link goes between the

left and right sides of the control horn sides and

is secured with a nylon lock nut.

3. Correct installation of ball link, flat washer and

brass spacer to servo arm shown below.

Note: Flat washer prevents ball link from

coming off brass ball.

19

7. Plug the 48” Extension into the female end of

the servo. Secure the servo connectors with an

Aeroworks Safety Clip Ensure the connectors

will not come apart from vibration or light ten-

sion.

6. Mount control horn using six wood screws as

shown.

8. Completed stab and elevator shown below. Re-

peat steps for other stab and elevator.

20

Rudder Installation

1. Gather the rudder, hinges, epoxy, Vaseline,

stir sticks, mixing cup and alcohol as shown.

Use 15-30 minute epoxy to ensure adequate

working and cleanup time.

RUDDER AND RUDDER SERVOS INSTALLATION

2. Prep all hinges for installation by applying

Vaseline petroleum jelly or light oil to the

hinge joint. This ensures no epoxy gets into

the hinge during assembly.

3. Mix epoxy in mixing cup and use a tapered

stick to apply the epoxy inside the pre-drilled

holes in the trailing edge of the fin. Apply

epoxy to one side of each hinge and insert the

hinge completely into the hole.

4. Ensure the hinge axis is vertical and parallel to

the trailing edge of the fin before epoxy cures.

Wipe away excess epoxy with alcohol wetted

wipes. Epoxy the hinges into the fin first and

allow epoxy to fully cure.

Note: Ensure you have free and full travel of each

hinge.

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AeroWorks Extra 300 ARF-QB Assembly Manual

AeroWorks Extra 300 ARF-QB Assembly Manual

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