Carl Goldberg Products EXTRA 300 Instruction Manual Download Page 13

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THE INSTRUCTIONS WILL LEAD YOU THROUGH THE
ASSEMBLY SEQUENCE, OCCASIONALLY SENDING YOU
BACK TO REPEAT STEPS. CAREFULLY READ EACH STEP
BEFORE YOU PROCEED TO DO THE INSTRUCTION.

1. Find all the parts that you will need to build the wing.

THEY INCLUDE:

(4) 3/8" SQ. X 35" SPAR BASS

(MIL #4528)

(2) SHAPED L.E BALSA

(MIL #4524)

(2) NOTCHED T.E BALSA

(MIL #4523)

(2) WING RIBS 2 & 8 BALSA

(D.C. 5310-3325)

(2) WING RIBS 3 & 6 BALSA

(D.C. 5511-3326)

(2) WING RIBS 4 & 1 BALSA

(D.C. 5512-3327)

(2) WING RIBS 5 & 7 BALSA

(D.C. 5513-3328)

(2) WING RIBS 1, 9 & 10 BALSA

(D.C. 5514-3329)

(4) WING CENTER SHEETING

BALSA

(D.C. 5515-3330)

(2) SHEAR-WEBS BALSA

(D.C. 5520-3332)

(2) WING JOINER

PLY

(2) BELCRANK PLATFORMS

PLY

(D.C. 5516-3483)

(2) DOWEL SUPPORT

PLY (D.C. 5516-3483)

(1) WING SUPPORT FRT

PLY (D.C. 5516-3483)

(1) WING SUPPORT REAR

PLY (D.C. 5516-3483)

(1) WING SUPPORT TIP

PLY (D.C. 5516-3483)

(1) SERVO PLATFORM PLY

(D.C. 5516-3483)

(1) DOWEL GUIDE PLY

(D.C. 5509-3480)

(2) INBOARD T.E.

BALSA (MIL #4526)

(5) 1/16" x 1/4" x 24" CAPS

BALSA (STK #4525)

(2) AILERONS

BALSA (MIL #4527)

(6) 1/16" x 2-3/4" x 35"

BALSA (SHT #4888)

(4) 1/16" x 2-1/2" x 35"

BALSA (SHT#4887)

(1) 3/4" x 33" NYLON FABRIC

(NYL #5210)

(1) 5/16" x 4-3/4" DOWEL

BIRCH (MIL #1759)

(2) .063" x 20-3/4" AILERON WIRE

(MTL #1230)

(2) .063" x 7" THREADED ROD

(MTL #1270)

(2) AILERON BELCRANKS

(NYL #1410)

(2) AILERON

BUSHINGS

(MTL

#1182)

(2) 2-56

NUT

(MTL

#1115)

(2) 2-56 x 1/2" MACHINE SCREW

(MTL #1041)

(2) #2

WASHER

(NYL#1461)

(4) NYLON SNAP-NUT

(NYL #1138)

(3) 1/16" I.D. x 1" BRASS TUBE

(BRS #1376)

(1) AILERON COUPLER BLOCK

(NYL #1427)

(1) 2-56 x 3/4" MACHINE SCREW

(MTL #1042)

(1) 2-56 x 1/8" MACHINE SCREW

(MIL #1040)

(1) SNAP LINK

(NYL #1405)

(8) FLEX POINT HINGES

(NYL #1449)

(1) C.G. CENTERLINE

TOOL

(NYL

#1425)

CONSTRUCTING THE WING (35 Steps)

Summary of Contents for EXTRA 300

Page 1: ...lease note bigger is not better A good 60 will do an excellent job A larger than recommended engine may overly stress your model causing structural failure WARNING A radio controlled model is not a toy It is capable of causing serious bodily injury and property damage It is the buyer s responsibility to build this kit correctly and to properly install the motor radio and all other equipment The fi...

Page 2: ...ILLER 1 1 2 x 8 x 12 FOAM PADDING 3 ROLLS OF COVERING FUEL PROOF PAINT FOR COWL AND WHEELPANTS OPTIONAL ITEMS SCALE PILOT PITTS STYLE MUFFLER SMOKE SYSTEM COMMERCIAL INCIDENCE GAUGE NECESSARY TOOLS AND SUPPLIES MISCELLANEOUS RUBBER BANDS WAXED PAPER MODELING KNIFE AND RAZOR BLADES SANDPAPER ASSORTED GRITS INCLUDING COARSE 80 MEDIUM 150 AND FINE 220 320 SANDING BLOCK T PINS at least 75 BUILDING BOA...

Page 3: ...dge may not exactly match the plan This is no problem as slight deviations in the outline or size will not noticeably affect flight performance Because the fuselage plugs together and is self aligning it is not built directly over the plan As you assemble the fuselage you will find the plan helpful in identifying parts and how things fit together The plan also shows the installation of a typical r...

Page 4: ...e a part is missing or damaged Also scrap is used in some building steps ABOUT THE WOOD IN THE KIT We strive to supply good quality materials in your kit Wood parts are inspected with regard to the function they will serve If an imperfection is spotted in a scrap corner of a die cut sheet and doesn t affect actual parts the sheet is considered acceptable Also internal stresses in wood are relieved...

Page 5: ...5 ...

Page 6: ...balsa sticks to fit the plan pinning and gluing as you go In cutting the diagonal trusses for the tail trim them to fit well If a bit oversize don t force them in place The pieces should fit before gluing 4 Place a 1 16 x 3 x 28 balsa sheet flush to the trailing edge T E of the stabilizer and mark the sheet width onto the stab sticks HINT In selecting the sheeting for the stab choose the firmer or...

Page 7: ...EVATOR HALVES They include 5 5 16 sq x 16 BALSA STICKS PT 4370 1 BIRCH PLY D C SHT 5518 CONTAINING 4 HORN MOUNTS PT 3481 1 D C BALSA SHT 5520 CONTAINING 2 HORN MOUNT CORES PT 3332 2 D C SHT 5517 BALSA CONTAINING 1 BALSA CORNER GUSSETS PT 3331 1 BALSA HORN MOUNT CORES PT 3331 2 Laminate the two 1 32 PLYWOOD HORN MOUNTS to the 3 16 and 1 16 BALSA CORES Make two such assemblies one for each elevator ...

Page 8: ...T ASSEMBLIES and the CORNER GUSSETS into the frame 1 Collect the items needed to construct the VERTICAL FIN They include 3 3 16 x 5 16 x16 BALSA STICKS PT 4369 2 1 16 x 3 x 18 BALSA SHEETS PT 4538 2 Cover the fin portion of the plan with waxed paper Trim the 3 16 x 5 16 balsa sticks and pin over the plan gluing as you go VERTICAL FIN CONSTRUCTION 4 Steps ...

Page 9: ... the fin as you go 4 Flip the fin over and repeat the sheeting operation as illustrated THIS COMPLETES THE VERTICAL FIN CONSTRUCTION PUT IT ASIDE UNTIL YOU ARE READY TO INSTALL THE HINGES 1 Collect all of the parts you will need to construct the RUDDER They include 3 5 16 sq x 16 BALSA STICKS PT 4370 1 D C BALSA SHT 5517 PT 3331 CONTAINING 1 3 16 HORN MOUNT 2 D C BALSA SHT 5520 PT 3332 CONTAINING ...

Page 10: ... complete this section In addition to the following kits parts you wiII need a small drill drill bits a modeling knife a sharp pencil a sanding block and fine and medium grit sandpaper 9 JET HINGES PT 1667 1 D C PLY SHT 5519 PT 3482 CONTAINING 1 ROUNDING TOOL 1 R BEVEL TOOL 1 AE BEVEL TOOL 1 CG NYLON CENTERLINE MARKER PT 1425 2 From the plan transfer the hinge locations onto the rudder and the ele...

Page 11: ...ces hinged and assembled check the alignment For good control response the hinge gap should be as small as possible but s h o u l d allow for full deflection when needed Remove the hinges 6 Assemble the two bevel tools and install a strip of medium grit sandpaper as shown 7 Using the tool marked R bevel the rudder side of the hingeline to a point at the centerline You may want to bevel near the ai...

Page 12: ...es 11 Finish sand all of the tail parts using a sanding block and fine sandpaper HINT Sanding will cause gaps at the joints to fill with balsa dust Use this to your advantage by putting a drop of thin C A glue into the gap Then sand after the glue dries Separate the fin from the rudder and the elevators from the stabilizer THIS COMPLETES THE CONSTRUCTION OF THE TAIL SECTION PARTS PUT THEM ASIDE UN...

Page 13: ... WING SUPPORT FRT PLY D C 5516 3483 1 WING SUPPORT REAR PLY D C 5516 3483 1 WING SUPPORT TIP PLY D C 5516 3483 1 SERVO PLATFORM PLY D C 5516 3483 1 DOWEL GUIDE PLY D C 5509 3480 2 INBOARD T E BALSA MIL 4526 5 1 16 x 1 4 x 24 CAPS BALSA STK 4525 2 AILERONS BALSA MIL 4527 6 1 16 x 2 3 4 x 35 BALSA SHT 4888 4 1 16 x 2 1 2 x 35 BALSA SHT 4887 1 3 4 x 33 NYLON FABRIC NYL 5210 1 5 16 x 4 3 4 DOWEL BIRCH...

Page 14: ...g the arrows as shown Pin or tape the plan to the building board and cover with waxed paper 3 Lay a shaped LEADING EDGE over the plan and cut the angle at the centerline Repeat this step on the other L E Next place the notchedTRAILING EDGE over the over the plan aligning the notches to insure that you cut the correct end Cut the angle at the centerline and then repeat this step on the other notche...

Page 15: ...E on the support tabs with the cut end at the centerline Press the ribs into the notches and glue Remove the other ribs from their sheets IMPORTANT Save the horseshoe shaped punch out in Rib 4 as you will need it for Step 29 Place the remaining ribs into the notched T E and onto the spar but DO NOT GLUE Make sure that you correctly install Rib 7 as shown Match the bellcrank support slot direction ...

Page 16: ...ing Edge the Spar and the Trailing Edge 9 Glue the balsa shear webs to the front side of the spars centering the shear webs between the wing ribs NOTE IF YOU ARE USING THE TWO AILERON SERVO SYSTEM OMIT THE FOLLOWiNG Drill a 1 16 diameter hole at the center mark on each of the aileron bellcrank supports and glue the support between Ribs 6 and 7 10 Edge glue two sets of three 1 16 x 3 x 36 balsa she...

Page 17: ...eting to the L E shoulder ribs and spar pinning or taping to secure until dry Glue the 1 16 x 2 1 2 x 36 Trailing Edge sheeting to the notched T E and the wing ribs 13 To glue the center sheet in place first install the front and back pieces Then slide the center piece in tightly Trimming may be necessary Place some glue on the wing tip sheeting and slide in place Cut the 1 16 x 1 4 balsa capstrip...

Page 18: ... BACK TO STEP 3 MAKING SURE TO WORK OVER THE OTHER HALF OF THE WING PLAN REPEAT THE CONSTRUCTION SEQUENCE FOR THE OTHER WING PANEL AFTER COMPLETING STEP 15 FOR THE SECOND TIME GO ON TO THE NEXT STEP 16 Glue the front rear and tip wing fixture supports as shown 17 Locate the wing fixtures and pin to the plan Align the marks on the tip fixtures to the spar on the plan 18 Laminate the top and bottom ...

Page 19: ...oiners and spars for maximum bond Then apply 20 MINUTE EPOXY to the wing joiners and insert into the wing around the spars Clamp to form a gap free joint Check to see that the wing is firmly on the fixtures while the joiners are drying 21 Laminate the rear portion of Rib 1 NOTE IFYOU ARE PLANNINGTO USETHETWO AILERON SERVO SYSTEM DO NOT PUNCH OUT THE CENTER MOUNTED SERVO BLANK AS SHOWN HERE GLUE IT...

Page 20: ...port tabs in Rib 2 23 Crack off all of the support tabs Glue the remaining pretrimmed L E sheeting to the wing Pin or tape to secure until dry Fit and trim the T E sheeting and glue to the wing NOTE IF YOU ARE USING THE TWO SERVO OPTION GO ON TO STEP 31 24 Bend a 5 16 x 900 angle at one end of the 063 diameter x 20 3 4 wire pushrod Install an aileron bellcrank onto the bend See plan for correct or...

Page 21: ...ng the plan for reference cut the aileron pushrod exit holes in the T E sheeting 26 Make to pushrods to fit the template shown here 27 Install the threaded pushrods onto the bellcranks and secure with a snap nut Place a drop of JET glue onto the snap nuts Referring to the plan fix the bellcranks in the neutral position with a T pin 28 Assemble the aileron coupler ...

Page 22: ...the neutral position and solder the coupler tube to each pushrod The other brass tubes will be positioned after the servo is mounted 30 Connect the aileron servo to the pushrod Locate the servo so that the bellcranks are in the neural position Tighten the setscrew and mount the servo In each wing half center the brass tubes on the aileron pushrods at Rib 4 Glue the horseshoe shaped balsa piece ret...

Page 23: ...m the building board 32 Sand flat the end ribs and glue the balsa tip rib to both tips Sand the perimeter to match the airfoil 33 Sand the wing blending all the seams and joints Use a tack rag to remove all of the dust when finished 34 Starting at the front of the servo cut out completely wrap the center of the wings with 3 4 nylon tape Smear glue through the fabric weave using a plastic bag to pr...

Page 24: ...the fit Then sand the aileron to the tip plane of the wing NOTE Permanent assembly of the ailerons to the wings as well as control horn installation is done after covering IF YOU ARE INSTALLING ONLY ONE SERVO THE WING CONSTRUCTION IS NOW COMPLETE NOTE The two servo option should be used for aircraft using an engine larger than a 60 2 cycle 1 Collect the following parts needed to install an aileron...

Page 25: ...ssets to the servo mounts and fasten the assemblies to a servo 5 Glue a corner gusset to each corner of the servo bay as shown Fabricate the balsa hatch and drill a 1 16 diameter hole in each corner Center the servo arm in the slotted hole of the hatch cover to locate the servo Remove the hatch and glue the servo gussets and mounts to the platform 6 After the wing is covered and with both the serv...

Page 26: ...HEET PT 4602 1 BASS WING MOUNTING BLOCK PT 4372 1 1 4 PLY LANDING GEAR BLOCK PT 4373 2 BASS MOTOR SPACER PT 4374 1 1 2 x 7 BALSA GUSSET PT 4217 2 1 8 x 1 2 x 18 BALSA STICK PT 4376 6 6 32 BLIND NUT PT 1124 6 6 32 x 1 1 4 SOCKET HD SCREW PT 1024 2 6x3 4 WASHER PT 1144 4 6 x 3 4 SHT METAL SCREW PT 1082 2 MAIN LANDING GEAR WIRE PT 1322 2 MOTOR MOUNT PT 1466 2 Carefully remove the parts from the die s...

Page 27: ...er the AF side of the firewall Measure 1 2 of the total distance between the mounts from the scribe mark on the firewall to one of the mounts With the holes on the vertical scribe marks on the firewall mark all four mounting bracket locations Drill a 5 32 hole at each location Turn the firewall over and insert the four 6 32 blind nuts Seat them with a soft hammer blow Coat the edges of the nut wit...

Page 28: ...ng gear wire slots are in line 9 With the triplers face to face tape the fuselage sides together at the rudderpost end Use a scrap piece of 3116 balsa spacer between the sides Install Former D balsa doubler forward and secure with a rubber band Install Formers E and F using rubber bands to secure at each former 10 Slide the fuselage top under the rubber bands and press into position Loosen the tap...

Page 29: ... the fuselage over the TOP VIEW of the plan and check the alignment Use small pieces of masking tape to secure the structure as you go Sight check down the fuselage to insure against twist 13 When the fuselage is perfectly aligned glue all of the seams created by the sides top bottom and formers ...

Page 30: ...facing out Glue Former C to the landing gear block and the triplers 15 Glue in Former B Check that the former is flush with the fuse side slot 16 Glue the FIREWALL onto the fuselage assembly Make sure that the blind nut flanges are on the inside 17 Glue the bottom front piece in place ...

Page 31: ...the doublers When you have a proper fit Epoxy in place 21 Install the gusset into the slot in the slant former and down into the notches in the doublers The gusset should also rest on the wing mounting block When you are satisfied with the fit glue in place 22 For the next few steps you will need the wing Place the fuselage on a stable flat surface Insert the wing pin dowel into the hole in Former...

Page 32: ...rom the fuse and drill a 5 32 hole using the pilot hole as a guide Test bolt the wing to the fuselage and check to make sure the tip to tail dimensions are still equal 24 Trim and glue the 1 2 balsa triangle stock behind the firewall 25 Glue in the top reinforcement 26 Glue in the remaining triangle stock as shown ...

Page 33: ...NTERLINE ONTHETOP SHEET AND THE FUSE TO INSURE A CORRECT FIT Sand the edges in line with the firewall and Former BB 29 Install Former FF directly above Form F and at a 900 angle to the fuse top 30 Mark the centerline onto the horizontal stabilizer and on the stab platform of the fuselage Glue the stabilizer to the platform locating it on the centerlines and against Former FF Check the stabilizer t...

Page 34: ...ooth fit 34 When satisfied with the fit apply glue to the formers fuselage sides fin and stab Quickly wrap the plywood down to the fuselage and tape in place until dry 35 Bevel the plywood edge at the fuselage lap joint and sand the edge flush with the slant former Fill the step with CGM Model Magic filler Apply additional filler to the fin and stabilizer seams and blend to create a smooth transit...

Page 35: ...r Align the half moon notches with the wire and keep the root end parallel to the fuse bottom 4 Edge glue the two 1 16 x 2 7 8 x 10 BALSA SHEETS together and cut 6 1 2 cross grained strips 6 1 cross grained strips 5 Laminate three 1 strips to the ply failing Wet the balsa if necessary to bend into position 6 Repeat the process with the 1 2 strips on the front side of the fairing 7 Sand the complet...

Page 36: ...EW PT 1048 2 2 WASHER PT 1139 2 Mount the wing to the fuse Position the two rails on top of the wing as shown Tape to the wing if you wish Referring to the plan for the distance between the two Formers CC glue them to the rails Use the 1 4 dowel as an alignment pin to the fuselage Former BB Install the rear spreader into the slots in the rails and glue 3 Drill a 3 32 hole through the rail and the ...

Page 37: ...the canopy deck up to the canopy crease ASSEMBLING THE WHEEL PANTS 6 Steps 1 Clean up the edges of the pant halves by gently sliding them over sandpaper on a flat surface 2 On both the outer and the inner pant half drill a 3 16 hole at the axle location Glue the two support plates to the inner pant half Glue the axle support plate to the outer pant half aligning the center mark on the plate concen...

Page 38: ...into the pant groove and permanently install the nylon strap With the wheel in the center of the pant tighten set screws in the collars allowing the wheel to spin freely 6 Install the tailwheel bracket Secure using two 2 x 3 8 screws With the horn bracket on the wire notch the bottom of the rudder and glue in the bracket Install a 1 1 4 diameter wheel ASSEMBLING THE ENGINE COWL 9 Steps 1 Carefully...

Page 39: ... sand smooth 7 Paint the cowl with a good quality fuel resistant paint 8 Permanently install the motor mounts to the firewall using four 6 32 x 1 1 4 socket head screws with washers NOTE If you are not using the engine spacers you must cut the screws so they do not interfere with the fuel tank Don t forget right thrust Screw the engine to the mounts using four 6 x 3 4 screws with washers 9 Slide t...

Page 40: ...its This is not a problem if the die cut servo tray D C SHEET 5519 supplied in this kit is used Solder the threaded coupler to the cables being careful to keep both assembly lengths equal With the servo in the neutral position trim tab centered attach the cables to the control horn and to the servo arm Adjust the snap links until the rudder is perfectly straight A ball bearing servo is recommended...

Page 41: ... setting and use the EXPO to soften the neutral For VTR inhibit the dual rate but set as follows AILERON 65 ELEVATOR 65 Note again that the max throws are in the high position on the travel gauges which is a good starting point From there adjust to personal taste Balance is very important as too far forward will cause the aircraft to want to nose over on takeoff particularly in grass Balance that ...

Page 42: ...IN A unique maneuver to observe so here s what to do ENTER A CONVENTIONAL SPIN The plane will go into a knife edge spin and will lose altitude very quickly so be advised SETTING UP AND FLYING THE EXTRA 300 AFTER 1 1 2 SNAPS 50 RUDDER THEN FULL RUDDER AND FULL AILERON FULL UP FULL DOWN FULL LEFT RUDDER AND FULL LEFT AILERON FULL UP FULL DOWN AFTER 1 OR 2 TURNS ...

Page 43: ...Length 16 25 Inches Typeface Sans Bold Color Blue Quantity 2 sides Height 4 50 Inches Length 23 00 Inches Slant 20 Degrees Typeface Univers Black Color White Quantity 1 Bottom Height 1 25 Inches Length 8 50 Inches Slant 20 Degrees Typeface Univers Black Color Qty Blue 2 Top White 2 Bottom Height 4 25 Inches Length 28 00 Inches Slant 20 Degrees Typeface Univers Black Color Qty Blue 2 lop White 1 Bo...

Page 44: ...For your next kit ...

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Carl Goldberg Products EXTRA 300, Instruction Manual

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