AeroWorks extra 330l Assembly Manual

Brand: AeroWorks

Model: extra 330l

Category: Toys & accessories

Type: Assembly Manual

AEROWORKS

33% EXTRA 330L

ASSEMBLY MANUAL

Congratulations! You have just become the owner of one of the highest quality ARF’s in both

material and workmanship in the industry. Aeroworks uses only hand select balsa wood and the

highest quality of light ply and hardwood available. All fiberglass parts are hand crafted and

inspected for imperfections. We have designed the Extra 330L to be lightweight, yet strong

enough to handle the aerobatic forces expected from a high performance airplane.

Thank you for purchasing the Extra 330L ARF. We wish you great success in both the assembly

and flying of your fully aerobatic airplane. If you have any questions or comments feel free to

call.

Aeroworks (303) 366-4205

(303) 366-4203 Fax

Or write to: Aeroworks

401 Laredo Unit “D”

Aurora, Co. 80011

www.aero-works.net

Before starting the assembly process of your new 330L Extra ARF, Please read through the

assembly manual carefully, and inspect all parts and any hardware for imperfections or damage.

It is important to notify Aeroworks of any damage or problems with the model immediately. If

you wish to return this aircraft for any reason a 15% restock fee will be charged to the customer.

In addition the customer is responsible for all return shipping cost.

Aeroworks cannot insure the skill of the modeler in the construction or use of this aircraft.

Therefore, will not be accountable for any property damage, bodily injury or death caused by this

aircraft.

The purchaser also accepts all responsibility of any and all structural or

mechanical failures.

EQUIPMENT REQUIREMENTS

AILERONS: Servo’s: 70 Ounce minimum, two per wing, Digital and metal geared servos are

not required, however are recommended.

ELEVATORS: Servo’s: 100 Ounce minimum one per stab. Digital and metal geared servos

are not required. However are recommended. Especially if you plan on doing 3-D style

maneuvers.

RUDDER: Servo’s: 150 ounce minimum, two servos in tandem on a pull – pull system.

Digital and metal geared servos are not required, however are recommended. If using a 7 pound

or heavier motor you may put the servos in the tail section of the plane.

THROTTLE: A high torque servo is not necessary, 48 ounce minimum. However, a reliable

and fast servo is recommended.

RECEIVER BATTERIES: We recommend you use two batteries. A primary 1700 MA pack

and a back up 1100 MA pack. You will plug the primary into the battery port of the receiver and

the secondary into any available port. It is important to use two switches one per battery. There

are after market battery backer systems that can also be used. It is up to the builder too chose

which system they want to use. But we do encourage using two batteries.

SWITCHES AND WIRING: It is important to use heavy gage wire ( 22 gauge ) for all

switches, batteries, and extensions.

FUEL TANK AND LINE: Use a 32 oz. fuel tank with large diameter size fuel line. Gas will

cause fuel lines to swell and come off brass fuel tubing. Be certain to always tie down your fuel

lines with clips or wire. It is also recommended to solder a barb onto the brass tubing for extra

security.

HARDWARE: It is recommended that you use the optional hardware package offered through

Aeroworks. If you do not use the Aeroworks package, we recommend that you use high quality

hardware designed for the larger planes.

RECEIVER: The use of a PCM receiver is recommended.

STEP A

TIGHTENING AND RE-SHRINKING THE COVERING

Open your kit slowly and take care not to damage 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 Ultracote covering. Due to the shipping process, heat and humidity

changes from different climates, the covering may become lose and wrinkle in the sun. If you

take the time to re-tighten the covering, you will be rewarded with a long lasting beautifully

covered model.

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. If bubbles persist, using a

small pin, punch holes in the bubble to relieve trapped air and reheat. We do not recommend

using a heat gun on any of the foam surfaces. Too much heat on one area may cause the foam to

melt underneath the wood.

After you have tightened up the covering, it is time to start the assembly of your Extra.

STEP B

FUSELAGE ASSEMBLY

With sharp xacto knife cut covering away from wing and stab tube holes. Cut covering away

from stab and wing anti-rotation holes. Cut covering away from aileron servo wire access slot in

fuse. There are rudder servo cut outs in both the radio compartment and the rear of the fuselage.

We recommend placing your rudder servos in the radio compartment using a pull-pull system.

Most engines on the market are to light to utilize the rudder servos in the tail of the aircraft. If

your engine weighs less then 7 pounds you must use the pull-pull system.

STEP C

WING ASSEMBLY

1) Locate the pre cut hinge slots in the wing and aileron. The model comes with CA style

hinges pre installed, but not glued into the control surfaces. If you wish to use the CA hinges

we recommend adding additional hinges to each surface and use thin foam safe CA when

gluing in hinges. We have used the CA type hinges with no problems. However, we highly

encourage the builder to use the nylon pinned style hinge, such as the Klett ¼ scale hinge you

will have to enlarge the hinge slot to accommodate the nylon hinge. Check surfaces for

alignment and glue hinges into the control surfaces. We recommend using slow set epoxy or

hinge glue. Be certain to give yourself plenty of aileron throw. Recommended throw is 35

degrees minimum up and down. We also recommend using Ultracote to seal all control

surfaces.

2) Locate servo locations on bottom side of wings and remove covering. (Two per aileron)

Attach servo extension leads to your servos, it will be necessary to “Y” the two servos

together and run one wing panel into the aileron port of your receiver and the other panel into

an auxiliary port of your receiver, designated by the manufacturer of your radio. Tie the pre-

installed nylon string to your servos and pull the servo wire through the wing. Install servos

into wings. It is important to secure the servo connectors with tape, wire or after market clip

to be certain the leads do not disconnect.

3) Locate hardwood blocks pre installed in the ailerons. Drill and tap the control horn locations

for an 8/32 bolt. Install the control horns so your linkage will be 90 degrees to the servo arm.

We recommend using the Rocket city control horn assembly #ROC 01A.

8-32

TAP

DEGREE

SERVO

ARM

CONTROL

HORN

4) When setting up the servo linkage, we recommend using 4-40 rod with a silver solder clevis.

It is very important to have all control linkages 90 degrees to the control surface and servo

arm. If more throw is required then the silver solder clevis will enable, then we recommend

using a du-bro swivel ball link at the servo arm for more movement.

SILVER SOLDER

CLEVIS

SERVO ARM AND CONTROL HORN AT 90 DEGREE

5) It is best to have the linkage as far in on the servo arm as possible and as far away from the

control surface as possible. If you are setting up the plane for 3D style flying. We

recommend using larger after market servo arms. It is important not to be closer then 1” from

the control surface with your control horn. If you get to close to the control surface you may

develop flutter. Special note: Remember to center all servos prior to connecting linkages to

servo. This will eliminate any binding when the radio is turned on.

6) Locate the hardwood dowel for the wing retainer bolt, located on the bottom of each wing.

Pre drill a 1/8” hole into the center of the dowel for the wing retainer bolt.

7) Slide aluminum tube through fuse and center in the fuse. Secure tube in fuse so tube cannot

move. A hose clamp works well for this. Slide both wing panels onto tube and push tight

against the fuse.

8) Drill and tap dowel and aluminum tube for 6-32 bolt.

Epoxy

hardwood in

wing tube

drill and tap

for 6-32 bolt

Wing

retainer

dowel

location

9) Leaving the aluminum tube in one wing panel, with wing retainer bolt secured, at all times,

will enable you to always find the tapped hole for the bolt. Remove one wing panel and

centered on the location of the retainer bolt, epoxy hardwood into the end of the aluminum

tube. Drill and tap hardwood for 6-32 bolt. Repeat for other wing, remembering to keep tube

in one wing at all times. It will be necessary to round the top of the wooden block to fit inside

contour of aluminum tube.

STEP D

STAB AND ELEVATOR ASSEMBLY

1) Locate the pre cut hinge slots in the stab and elevator. The model comes with CA style

hinges pre installed, but not glued into the control surfaces. If you wish to use the CA hinges

we recommend adding hinges to each surface and sue thin foam safe CA when gluing in

hinges. We have used the CA type hinges with no problems, however we highly encourage

the builder to use the nylon pinned style hinge, such as the Klett ¼ scale. Check surfaces for

alignment and glue hinges into the control surfaces. We recommend using slow set epoxy or

hinge glue. Be certain to give yourself plenty of elevator throw. Recommended throw is 45

degrees minimum up and down. We recommend sealing all surfaces with Ultracote.

2) Locate servo location on bottom side of stabs and cut away covering. (One per stab) Using

the pre installed nylon servo wire attachment string, pull servo leads through stab. You want

to have the male end of the servo extension hanging out the stab and the female end hanging

out from the fuse. This will enable you to remove the stabs easily when necessary. It works

best to run one elevator servo extension into the elevator port of the receiver and the other

into an Aux port of the receiver designated by your radio manufacture. If you do not have a

radio capable of splitting the elevators into two different channels, it is possible to reverse

one servo and use the same port or channel in the receiver. There are after market servo

reverses that work well. Install servo into stabs. It is important to secure the servo

connectors with tape, wire or after market clip to be certain the leads do not disconnect.

3) Locate hardwood blocks pre installed in the elevators. Drill and tap block for control horn

locations for a 8/32 bolt. Install the control horns so your linkage will be 90 degrees to the

servo arm. We recommend using the Rocket city control horn assembly #ROC 01A.

Seal all hinge gaps

with Ultracote

covering

Rudder shown

CAP WITH

COVERING

CONTROL HORN

TOP VIEW

4) When setting up the servo linkage we recommend using 4-40 rod with a silver solder clevis.

It is very important to have all control linkages 90 degrees to the control surface and servo

arm. If more throw is required then the silver solder clevis will enable, then we recommend

using a du-bro swivel ball link at the servo arm for more movement.

5) It is best to have the linkage as far in on the servo arm as possible and as far away from the

control surface as possible. If you are setting up the plane for 3D style flying. We

recommend using larger after market servo arms. It is important not to be closer then 1” from

the control surface with your control horn. If you get to close to the control surface you may

develop flutter. Special note: Remember to center all servos prior to connecting linkages to

servo. This will eliminate any binding when the radio is turned on.

6) Locate the hardwood dowel for the 4-40 stab retainer bolt, located on the bottom side of each

stab. Pre drill a 1/8” hole into the center of the dowel for the stab retainer bolt.

7) Slide aluminum tube through fuse and center tube in fuse. Secure one end of tube in fuse so

tube cannot move. Slide one stab panel onto tube and push tight against fuse.

STAB RETAINER

DOWEL

MEASURE

EQUAL

DISTANCE

TAP FOR

4-40

BOLT

8) Drill and tap dowel and aluminum tube for 4-40 bolt. Secure stab to tube with 4-40 bolt, then

slide other stab onto tube and repeat retainer bolt installation. Be certain both stabs are tight

against fuse.

9) Leaving the aluminum tube in one stab panel, with wing retainer bolt secured, at all times

will enable you to always find the tapped hole for the bolt. Remove one stab panel and at the

location of the retainer bolt, epoxy hardwood into the end of the aluminum tube. Drill and

tap hardwood for 4-40 bolt. Repeat for other stab, remembering to keep tube in one stab at

all times.

STEP E

ENGINE BOX ASSEMBLY

1) Cut 1/8” ply engine box sides to correct length to accommodate your engine size. Be sure to

leave room for soft mounts if used. Soft mounting is not required. An easy way to

determine the correct length of box sides is to slide the cowl over Former F1 approximately

1”. Measure from front of former F1 to front of the cowl. Now measure the length of your

engine. Subtract the engine length from your first measurement. This should be the required

length for your engine box sides. It is always a good idea to cut the engine box sides slightly

shorter then needed, approximately ½”. This will allow you to make adjustments by adding

spacers between firewall and engine. Adding a spacer will also allow for the rear cylinder to

be spaced away from the firewall to allow for better cooling. *Be certain to check sides,

one is longer then the other, this is to put in the right amount of right thrust. Also

firewall has been beveled.

Engine box parts

Measure From F1 to end of cowl to get correct box length

2) Slide engine box sides through former F1, slide notch of engine box sides into former F2.

Square sides to former F1. Using epoxy, glue sides to F1 and F2.

F1 F2

Glue box sides to

Formers F1 an F2

Tri stock for extra

reinforcement

3) Epoxy 3/8” ply firewall to the inside of the engine box sides and flush with the bottom of

sides.

4) Cute 1/8” lite ply engine box floor to correct length. The floor should rest on bottom of sides

and firewall and butt up next to former F1.

5) Epoxy engine box floor to the bottom of sides, firewall, and front of former F1. Be certain to

square all parts to former F1.

6) Use 3/8” balsa tri-stock reinforcement at all glue joints. Behind firewall reinforce glue joint

with 3/8” spruce tri stock.

7) Install ¼” lite-ply box top to the engine box assembly. Box top should fit to the rear of the

firewall and up next to Former F1. Glue to the top of the box sides. Sand flush with box

sides. NOTE: It is best to do this step after your engine has been mounted and all other

necessary installations including ignition, fuel tank etc.

Install box top

STEP F

LANDING GEAR

1) Drill or tap axle hole in gear to fit your axle. We recommend 3/16” dia. Axle.

2) Install axles using thread lock or lock nut.

3) Draw a centerline, front to back, down both aluminum landing gear and ply mounting plate.

4) Align center marks.

5) With gear centered on center line and front to back on mounting plate, drill four equally

spaced holes through gear and mounting plate, two front and two back, to accommodate

10-32 bolts.

Use 10/32 bolts and blind nuts to attach gear to block. Special note: Use thread lock on all

gear bolts.

STEP G

FUEL TANK FLOOR

1) Locate the wood pack with the necessary wood parts for the fuel tank floor.

1 5” x 7 ½” Lite-ply tank floor

1 ¼” x 5/8” x 5” Balsa

4 3/8” x 5” Balsa tri stock

2) Glue ¼” x 5/8” x 5” balsa to top of gear former.

3) Glue 3/8” balsa tri-stock to both sides of former F2

4) Glue 1/8” lite ply tank floor to top of balsa strips.

Glue ¼” balsa to top of

gear former

Glue 3/8” balsa tri-stock

to both sides of former

Glue tank floor to

top of balsa and next

to wing tube phenolic

You may drill

optional

lighting holes

in tank floor

Tape foam to bottom of fuel tank and nylon

tie tank to tank floor

STEP H

FIN AND RUDDER ASSEMBLY

1) Locate the hardwood block pre installed in the rudder for the control horn. Drill and tap for

8-32 all thread. Install all thread into rudder and secure with flat washer and nut on each side.

You should have approximately 1” of bolt on each side of the rudder for the mounting of the

control horns. Use thread lock to secure.

2) Trail fit fin to fuse. Remove fin. Apply epoxy to all surfaces to be glued. Slide fin into the

fuse. Use tape to hold in place while assembly dries. (NOTE) Remove covering from all

glue areas and make sure the fin is glued to the rear of the fuse.

3) Locate pre cut hinge locations and glue hinges into fin and rudder. We recommend epoxy or

hinge glue. We recommend sealing all control surfaces with Ultracote.

STEP I

CANOPY/HATCH INSTALLATION

1) Using scribe lines as reference, cut out canopy.

2) Trial fit canopy to hatch cover. Do all painting/prep work, dash panels and pilot installation

prior to gluing canopy. (NOTE) We recommend you remove the covering from the cockpit

floor location. We use an automotive trunk spatter spray paint (Grey or White) and paint the

floor location to complete a finished look.

3) Glue canopy to hatch cover. We use 3M stripping tape to finish out the canopy.

STEP J

COWL INSTALLATION

It is first recommended to install engine per manufactures recommendations.

Engine thrust line is 1 3/4” down from top of fuse box sides. 2 to 3 degrees of right thrust and 0

degrees of down thrust. It will be necessary to offset the engine to the left (pilot view) 3/8” to

compensate for right thrust. This will allow the center of the engine to exit at the center of the

cowl.

1) Fit cowl to fuse, cutting out where needed to accommodate engine.

2) When fitting cowl to fuse. Use a 4” spinner to ensure proper alignment with spinner plate of

cowl.

3) When satisfied with fit drill two 1/8” holes on each side of cowl and through fuse sides.

Approximately ¼” from rear of cowl.

4) Use 4-40 bolts and blind nuts to attach cowl to fuse.

NOTE: We recommend using metal/rubber washer to secure bolt.

5) Due to shipping and packaging, you may have a fine haze on the beautifully painted cowl. If

you do, using a fine rubbing or polishing compound will eliminate the haze effortlessly. You

can find this product at any automotive store.

STEP K

INSTALLING WHEEL PANTS

1) Make a notch in the wheel pant and lite-ply mounting plate with a Dremel drum sander.

Make the notch deep enough to let the wheel pant slide over the axle to the desired height.

2) Align the wheel pant to the gear and with 1/8” drill bit, drill two equally spaced holes through

gear and wheel pant. Mount wheel pants to gear with 4/40 bolts and blind nuts.

STEP L

CONTROL SURFACCE THROW

1) Elevator High rate 20 degrees up and down

Low rate 12 degrees up and down

3-D rate 40 degrees up and down

2) Rudder High rate 60% deflection

Low rate 30% deflection

3-D rate Full deflection

3) Aileron High rate 24 degrees up 24 degrees down

Low rate 18 degrees up 18 degrees down

3-D rate 35 degrees up 35 degrees down

The throws given are to be considered only a starting pint. Adjust the throws to accommodate

your style of flying.

STEP M

BALANCING (CG) 1/2" to 3/4" IN FRONT OF WING TUBE

1) Balance the 330L with fuel tank empty otherwise ready to fly.

STEP N

FLYING

We believe the Extra 330L will be one of the finest flying airplanes you will ever fly. The 330L has no bad

habits and very slow speed stall characteristics.

Inverted flight is nearly hands off and knife edge flight takes little or no mixing to remain straight and true.

Remember the Extra is a large aircraft and picks up speed quickly when coming out of split S type

maneuvers or when needing straight downward. (Always throttle back).

If you have followed the assembly manual instructions and have balance your Extra properly, you will be

rewarded with a highly aerobatic, stable and predictable flying airplane.

PHOTO SHEET

Mount ignition in engine box. Protect with

foam and screw or nylon tie down.

Always protect

wires

Secure battery with

hooks and rubber

bands

Nylon tie fuel tank down. Receiver is located behind wing tube.

Ohio superstar Haige

style tail wheel

Rudder servos location

HARDWARE PACKAGE

PACKING LIST

33% Edge 540 T, Extra 330 L

8 4/40 x ¾ bolts DU 572

12 4/40 blind nuts DU 135

14 #4 flat washers DU 323

4 10/32 x ¾ bolts DU 580

4 #10 flat washers DU 586

4 10/32 blind nuts DU 584

4 4/40 x ½ bolts DU 571

2 4/40 x 1 ¼ bolts CA 0420

2 3/16 axles DU 249

4 3/16 collars DU 141

2 4” kavan wheels 0166

1 Ohio large haigh Tailwheel

9 4/40 threaded rods DU 144

9 4/40 kwick links solder DU 305

8 Nelson control horns RK 01A

2 Packages hinges DU 257

2 6/32 x 1 ½ bolts DU 317

2 6/32 blind nuts DU 136

2 8/32 nuts DU 563

2 #8 flat washers DU 327

1 Threaded kwick link DU 601

1 Strip aileron horn set DU 103

1 4/40 pull pull DU 518

AeroWorks extra 330l Assembly Manual

Brand: AeroWorks

Model: extra 330l

Category: Toys & accessories

Type: Assembly Manual

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AeroWorks extra 330l Assembly Manual

AeroWorks extra 330l Assembly Manual

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