Extreme Flight Legacy Aviation Turbo Bushmaster Manual Download Page 5 | Manualshive

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1. Locate the 2 wing panels as well as the composite aileron and

flap  control  horns.    Use  sandpaper  to  scuff  the  portion  of  the
control  horn  that  will  be  glued  into  the  surface.    For  a  more
finished  look  you  may  wish  to  paint  your  control  horns  before
installation.   We used a black Sharpie to perform this task with
great  results.  Do  not  paint  the  portion  of  the  control  horn  that
will glue into the control surface!

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Summary of Contents for Legacy Aviation Turbo Bushmaster

Page 1: ...84 Turbo Bushmaster Copyright 2016 Extreme Flight 1 ...

Page 2: ...utics in order to be properly insured and to operate your model at AMA sanctioned flying fields only If you are not willing to accept ALL liability for the use of this product please return it to the place of purchase immediately Extreme Flight RC guarantees this kit to be free of defects in materials and workmanship for a period of 30 DAYS from the date of purchase All warranty claims must be acc...

Page 3: ...aster is loosely based on the full scale Turbo Beaver The Turbo Beaver is a well known and loved aircraft among bush pilots capable of STOL takeoffs and landings The Turbo Bushmaster is capable of these same maneuvers and so much more Big and light the Bushmaster is as gentle and forgiving as any trainer we ve ever flown making for a very enjoyable and relaxing flying experience Flip the rate swit...

Page 4: ...Let s begin Wing Assembly Wing Hardware 4 ...

Page 5: ...f the portion of the control horn that will be glued into the surface For a more finished look you may wish to paint your control horns before installation We used a black Sharpie to perform this task with great results Do not paint the portion of the control horn that will glue into the control surface 5 ...

Page 6: ...it the horns into their respective slots and trim any debris from the slot until the control horn seats properly against the control surface 4 Apply 30 minute epoxy to the aileron and flap control horn slots and to the scuffed area of the control horns It may be helpful to use a zip tie to push the epoxy into the slots 6 ...

Page 7: ...ys to do this and several adhesives you can use We will describe the way that we do it as this method has proven itself over many years of model building If you are new to this type of hinging process then I recommend that you install a single hinge first just to acquaint yourself with this method Before starting you will need to gather a few items to aid you as you proceed A 30 Minute Epoxy B A s...

Page 8: ...se a piece of pushrod or dowel to apply the epoxy to the hinge hole 9 Apply epoxy to the barbed section of the hinge on one side and insert it into the hole until the center of the hinge is centered on the hinge line Using a paper towel soaked with acetone or denatured alcohol wipe away any epoxy that has been squeezed out of the hole 8 ...

Page 9: ...wing maximum movement of the control surface 11 As a final step before setting the wing aside to dry do a final cleaning of the hinge knuckles with a paper towel soaked with denatured alcohol or acetone to remove any epoxy residue If you find any of the hinges are stiff after drying apply a drop of acetone to each hinge with a Q tip and move the surface back and forth several times to loosen it up...

Page 10: ...at shrink tubing or a wire keep 13 Use the manufacturer supplied mounting hardware to install the servos with the output shaft toward the LEADING EDGE of the wing Electronically center the servo and install 1 25 servo arms onto the servo spline The servo arms should be parallel to the hinge line when centered It is very important that you use the same length servo arms for both flap and aileron se...

Page 11: ...e pushrod into the ball link makes this task much easier Be very careful not to screw the pushrod in too far and damage the ball link 15 Use the supplied 2mm bolts washers and nuts to affix the pushrod to the servo arm and control horn It is imperative to attach the ball link to the bottom of the servo arm to achieve full deflection 11 ...

Page 12: ...me sanding may be required for best fit While the fences are temporarily installed on the wing use 2 pieces of painters tape to mark their location on each side of the fence This will aid in alignment and prevent excess glue from getting on the covering 12 ...

Page 13: ...Use 30 min epoxy to attach the fences Wipe away any excess epoxy with a paper towel soaked in acetone Be sure to remove the tape before the epoxy fully cures Repeat this process for the other wing panel 13 ...

Page 14: ... Welders adhesive or Goop 18 Locate the landing gear fairings and black rubber tubing You will need to slice the tubing lengthwise on one side Use a sharp hobby knife and starting at one end gently cut through only one wall of the tubing being careful not to cut through the second side Once the tubing has been cut place it around the top of the landing gear faring and secure it with CA 14 ...

Page 15: ...19 Locate the carbon landing gear axles wheels and fasteners from the landing gear hardware package 15 ...

Page 16: ...20 Attach the landing gear to the fuselage using the supplied bolts and washers The landing gear has a slight airfoil make sure that the thicker part of the gear is facing the nose of the airframe 16 ...

Page 17: ...ainst the bottom of the fuselage Use a piece of painters to mark their location Remove the fairing and apply a thick bead of Goop to the carbon gear just above the tape line Slide the fairing back into place and secure with tape until dry 17 ...

Page 18: ...22 Locate the 2 axles 2 locking nuts 2 wheels 4 wheel collars and 2 washers and mount the wheels as shown 18 ...

Page 19: ...Horizontal Stab and Elevator Assembly Stab elevator Hardware kit 19 ...

Page 20: ...n on the building table and remove the covering from the control horn slot on the RIGHT side This will be the Left side when installed Glue the control horn in place with 30 minute epoxy 24 Insert the elevator section Upside down and backwards into the Stab Elevator slot 20 ...

Page 21: ...21 ...

Page 22: ...25 Now insert the horizontal stabilizer and check that the hinge holes match the holes in the elevator 22 ...

Page 23: ... a good idea to use a tape measure and triple check all measurements before gluing the Stabilizer in place Measure from a fixed point on the wings to the tip of the Stabilizer on both sides Adjust the stab until both sides are the same Take your time with this step as proper alignment is critical 23 ...

Page 24: ...y applying CA along the joint between the stab and the fuse Make sure to apply CA to the top and bottom of the stab 28 Once the horizontal stab is glued in place use the same technique to install the elevator hinges and control horn that we used for the aileron and flaps 24 ...

Page 25: ...25 ...

Page 26: ...29 Locate the fences for the horizontal stab and attach them with medium CA Make sure to confirm alignment with the vertical stab 26 ...

Page 27: ...e is to be used when building the airframe for float flying only as it will occupy the space for the tailwheel 31 Place the fuselage upside down in a stand the Extreme Flight 4 in 1 stand works great Locate and remove the covering from the 3 holes that the lower keel locks into 27 ...

Page 28: ...e fuselage Use tape to secure while drying Be sure to check for proper alignment 33 Attach an 18 servo extension to your elevator servo and using the manufacturer supplied hardware install it with the output shaft towards the rear of the fuselage Assemble the pushrod and install as shown in the picture 28 ...

Page 29: ...embly 34 Gather the tools and parts required for this step A 1 5 mm Hex Driver B Phillips head screwdriver C Thread locker D Tail wheel E Tail wheel axle F Tail wheel Mounting Bracket G Wheel Collar H Tiller arm 29 ...

Page 30: ...35 Attach the wheel to the Axle with the supplied wheel collar NOTE It is a good idea to file a small flat section on the axle for the wheel collar set screw to mate up to 30 ...

Page 31: ...36 Next install the carbon fiber mounting bracket and tiller arm Make sure to align the screw in the tiller arm with the flat spot on the tailwheel shaft and use thread lock 31 ...

Page 32: ...wheel Assembly For this step you will need A Assembled Tailwheel B Small Phillips head screwdriver C Thin CA D 3 wood screws E 5 64 Drill bit and Drill F Tailwheel pushrod Ball link and supplied hardware not pictured 32 ...

Page 33: ...37 Locate the Tailwheel pushrod 29 5 and threaded on one side and insert it through the hole on the pilot s upper left side and into the guide tube threaded end first 33 ...

Page 34: ...elage upside down in a stand 39 Place the tail wheel assembly up against the lower keel and center it on the bottom of the fuselage When you are happy with the placement use the holes in the tailwheel bracket as a guide and drill three 5 64 holes Add a drop of CA to each hole and then attach the Tailwheel using the supplied wood screws Now would be a good time to thread the ball link onto the cont...

Page 35: ...Vertical Stab Rudder Assembly Rudder hardware kit 35 ...

Page 36: ...tab and rudder you will need to locate the following A Vertical stab and rudder assembly B Rear vertical stab wedge C Carbon fiber vertical stab tube D Rudder control horns E 4mm cap head screw F 30 min epoxy G 3mm Hex driver 36 ...

Page 37: ...ns 41 Once the epoxy on the rudder hinges has cured test fit the rudder control horns Make sure to scuff the bases of the control horns It may be necessary to trim the base of one of the control horns to ensure that both horns fit properly into the control horn slot 37 ...

Page 38: ... fit of the control horns mix up a small batch of epoxy and install the rudder control horns 43 Insert the carbon fiber vertical stab tube into the vertical stab rudder assembly Then use your hobby knife or soldering iron to 38 ...

Page 39: ...the right side of the vertical stab to reveal the mounting hole 44 Slide the completed assembly into the vertical stab tube socket and secure the stab to the fuselage with a 4mm cap head screw Don t forget to use thread lock 39 ...

Page 40: ...45 Deflect the rudder to one side and install the vertical stab wedge Wick in a bit of CA to hold it in place 40 ...

Page 41: ... space provided on the battery tray and electronically center it Note that the output shaft of the servo is towards the rear of the airframe 47 Locate the EZ connector and mount it on the innermost hole on the pilots left side of the servo arm Put a drop of thin CA on the bottom nut to prevent it from backing out 41 ...

Page 42: ...into the EZ connector center the tailwheel and tighten the cap screw Make sure you use thread lock 49 Next install the pull pull cables and ball links It is easiest to build the rear half rudder side of the cables and install them 42 ...

Page 43: ...e braided wire Insert the wire through the hole in the brass fitting and insert the end of the wire back through the crimp Loop the wire around the crimp and insert again into the crimp Carefully use a pair of side cutters to crimp the wire in several places 50 Follow this same method to assemble the linkages in the forward part of the system that will attach to the servo arm The cables should cro...

Page 44: ...t do not make them guitar string tight as doing so can overstress the servo Windscreen Installation 51 Next we ll install the windscreen You have the choice of gluing the windscreen into place with a specialty glue like Pacer Formula 560 44 ...

Page 45: ...mark a cut line with the tape being placed inside the line where you will trim the canopy This will help to prevent the canopy edges from splitting while being cut 54 Test fit and trim as needed Attach canopy with a thick bead of canopy glue and tape in place with painters tape and allow to dry overnight Alternately you could sew the canopy in place with multiple small screws Photos of both attach...

Page 46: ...46 ...

Page 47: ...Locate the following and prepare the motor for mounting A Motor Torque 4016 500 B ESC Airboss 80A C Supplied Torque hardware kit with X mount and Bolt on Prop Adapter D 2 5mm Hex Driver E 3mm Hex driver F Small Phillips head screwdriver G Thread lock 47 ...

Page 48: ...56 Secure the prop adapter to the motor with supplied socket head cap bolts using blue thread lock on each bolt 48 ...

Page 49: ...haft and secure in place with the set screw Place a small drop of thread lock on the threads of the set screw to prevent it from backing out 58 Attach the Supplied X mount with the 4 Philips head screws Again use a drop of thread lock on each screw 49 ...

Page 50: ...59 Locate the 4mm black cap bolts and washers to attach the assembled motor to the firewall 60 Using a drop of thread lock on each bolt attach the motor to the firewall 50 ...

Page 51: ...the ESC to the bottom of the motor box 62 Connect the wires of the ESC and the motor and secure them to the motor box with nylon cable ties 63 Attach a 12 servo wire extension and a 8 10 battery extension to the ESC and route them into the fuselage There are 51 ...

Page 52: ...2 locations in the fuselage for mounting external ESC and BEC switches If you are going to use a switch go ahead and mount it now 52 ...

Page 53: ...Mounting the Cowl 64 Locate the following A Cowl B Exhaust stacks C Contact adhesive or Epoxy D Sandpaper E Painters tape F Drill bit G Felt tip pen 53 ...

Page 54: ...65 Scuff the bottom of the exhaust stacks and the indentions on the cowl where they will mount 54 ...

Page 55: ...66 Using contact adhesive or epoxy glue the exhaust stacks to the cowling and hold them in place with painter s tape until the glue is dry 55 ...

Page 56: ...with one of the 4 cowl mounting tabs Use a felt tipped pen to mark the location of the center of each mounting tab 68 Slide the Cowl into position Install the spinner onto the motor shaft for reference and once satisfied with the cowl position roll the tape back into place and secure the cowl Use a 1 16 drill bit to drill a hole at the location of the dot on each piece of tape 56 ...

Page 57: ...69 Remove the tape and cowl and add a drop of CA to each hole Mount the cowl with the 4 of the small wood screws included with the kit 57 ...

Page 58: ... bottom of the fuselage 71 Mount your receiver as shown and tidy up the servo extensions Pictured mounted to the battery tray are 2 multi plug extensions to make plugging in your aileron flap servo leads easier Affix a strip of Velcro to the battery tray and retain your battery with a Velcro strap 58 ...

Page 59: ...72 Install your prop and spinner 59 ...

Page 60: ...insert the servo extensions into the fuselage Secure the wings be inserting the nylon wing bolts into the holes in the fuselage and threading them into the blind nut in the wing root 74 Attach the struts using the supplied 3mm cap head screws You may find it easiest to start with the wing attachment first 60 ...

Page 61: ...ered on the tray just forward of the wing tube as shown in the photo for step number 71 It is recommend you first fly the model in standard configuration to get used to its flight characteristics before beginning to experiment with flaps When deploying flaps you will need to add an elevator mix that compensates for the flaps and provides a few degrees of down elevator A comprehensive and detailed ...

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