AEROMASTER Extra330L-50CC User manual

Extra330L-50CC

Instruction Manual

Congratulations and thankyou forpurchasingAeromaster s30% Extra330L.The Extra is

arguably oneof themost renownedaerobatic aircraftever produced.WalterExtra whooriginally designedthe

Extra, named hisaircraft bythe horsepowerrating ofthe motorplaced inthem. Whatis an Extra330L? It s a

common questionwe hearfrequently.Afull scaleExtra330Lis reallyjust an Extra300Lfitted witha more

powerful 330hp LycomingAEIO 540 engine, these aircraft havebeen nicknamed theExtra330L.

Our aircraftwas designed with1,420 sq inches ofwing areawhile keepthe totalweight toa minimum.

Whether youwant an aircraft preciseenough to competein IMAC or3d until yourairsick, we believeour Extra

fits thebill. It s lightweight givesyou thestability inhigh-alpha totake itto theextremes ofthe flight

envelope. Iftumbling maneuversare yourthing, ourExtra330Lwill deliverwith pictureperfect waterfallsand

blistering tipspins that are notfor thefaint ofheart.

Webelieve youwill findthis tobe oneof thefinest flyingand easiestto assembleaircraft inthe market.Most

modelers willfind assemblyof thisaircraft simpleand straightforward.Werecommend thebuilder followthe

step-by-step instructions toachieve the bestperformance and toensure nothing wasover looked.This manual

also includes tipsections throughout thatmay help youin key areasduring assembly. Please familiarize

yourself with thismanual before assembly.

This manualis brokendown intonine chaptersfor simplicity:

Chapter 1- PartsInventory

Chapter 2- PreparationforAssembly

Chapter 3- LandingGear andTail WheelAssemblies

Chapter 4- CanopyHatch andCowling

Chapter 5- Engineand FirewallInstallation

Chapter 6- Cowlinginstallation

Chapter 7- ControlSurface andHardware Installation

Chapter 8- Radioand ControlSurface Setup

Chapter 9- FinalInspection andPre-Flight

Additional itemsneeded tocomplete thisaircraft, whichare notincluded:

Anengine, withinthe recommendrange, andpropeller

6 channelcomputer radioand receiverrecommended

Batteries andswitches (withregulators ifusing Ionbatteries)

Two aileronservos ratedat leastat 100ozof torque

Two elevatorservos ratedat leastat 130ozof torque

One rudderservo ratedat leastat 150ozof torque(250oz recommended)

One throttleservo withpush rodand links

Optional chokeservo withpush rodand links

One fuelingdot orfueling device

3 to4 feetof fueltubing

Foam rubber

3- /2inch spinner

30 to45 minuteepoxy

JB weldor RubberToughened CA

Abottle ofthin CA

Covering iron

Apull-pull cablewith crimpsand 4/40connecters

Various modelingtools forassembly

/2inch lowtack maskingtape

Chapter1

Parts inventory

Place an to ensureyour kitis complete:

If anyof theseparts aremissing immediatelycontactAeromasterAircraft duringnormal businesshours.

1 Fuselage

1 Firewall

1 Canopy fuselage access hatch

2 Wing panels(1 right and 1 left)

2 Ailerons (1right and 1 left)

2 Horizontal stabilizers (1 right and 1 left)

2 Elevators (1 right and 1 left)

1 Rudder

1 Fiberglass Cowl

1 Pair of fiberglass wheel pants

1 Composite landing gear

1 Pair of wheels

1 Tail wheel and tiller assembly

1 Carbon fiber wing tube 1-1/4 inch

1 Carbon fiber stabilizer tube /2inch

2 Nylon wing retention bolts

1 Carbon fiber pushrod

8 Metal pushrod ends

1 aluminum control horn set

1 20oz fuel tank

6 4/40 ball links

1 Set of additional various hardware

1 Vinyl graphics package

1 Pair of wing bags

1 Fuselage cover

1 Pair of stabilizer bags

Chapter2

PreparationforAssembly

Professionals utilizing premiumUltracote covering carefullycovered your model.Due to climatechanges

during shipping, themodels covering mayhave loosened and/orwinkled. It's agood habit togo over your

model with acovering iron toensure all joints,seams, and edgesare properly sealed.

Ultracote is atemperature sensitive filmthat seals andshrinks at lowertemperatures. Make sureyou set your

iron on alow temperature initiallyto get afeel for thecorrect temperature settingand adjust accordingly.

Higher temperatures willcause your coveringto over shrinkand distort.Also, use asock over youriron to

ensure a scratchfree finish.

Place an to ensure task completion:

1. Go over you model as necessary with a covering iron to insure all joints, seams, and corners are

sealed properly (figure1).

2. Use your iron to ensure the areas where cutouts are needed for your hardware are located and sealed

down, such as servos; tubes, and control horn mounting locations (figure 2).

Next, we ll need to cut out the covering at the locations for hardware and final assembly. Make sure you use a

sharp hobby knife so your cuts will be clean and straight.

3. Start with the fuselage, Locate and cut out the servo and stabilizer and wing tube locations (figure 3).

4. Locate and cut the location for the anti-rotation pins and mounting holes for the stabilizers and wings

(figure3 and 4).

5. Locate and cut the two mounting bolt locations for the canopy and the two pull-pull exits (figure 3

and4).

6. Locate and cut the servo mounting location for each wing half (figure5).

Place an to ensure task completion:

Chapter3

LandingGear andTailWheelAssemblies

Now that we re ready for assembly, we are going to start with the main landing gear first. You will need to

locate the following parts to begin assembly.

What you will need in this chapter for the main gear:

Fiberglass main gear

One pair of 3 / inch wheels

One pair of wheel pants

One pair of axles with one pair of compression or lock nuts

Two wheelcollars

Four 4-40 x / bolts, spring washers, flat washers, and blind

nuts 34

Four 8/32 x / bolts, spring washers and flat washers

Fuselage

/ and a 9/16 inch wrench

Blueloc-tite

Allen wrench for wheel collars

White wood glue such as Elmer s or epoxy as a substitute

Some scrap fuel tubing

Dremeltool

Not Provided:

1. Fasten the axles to the main landing gear with the lock nuts. Use care when tightening the lock nuts.

If over tightened it can damage the composite landing gear and cause it to fail. Only tighten enough to

lock the axle firmly in place and not rotate. Loc-tite is not

recommended here, as it will damage the nylon bushing (figure 6).

2. Slide one wheel collar or a 8mm piece of fuel tubing to the inside

of each axle. This acts as a spacer preventing the wheels from

moving side-to-side and making contact against the inside of the

wheel pants (figure 6).

3. Slide one wheel on each axle and fasten an additional wheel

collar. Place the collars as close to the wheels as possible but ensure

the wheels still rotate freely.Again, we don t want the wheel to

move from side to side and contact the wheel pants. Also, we

recommend the use of loc-tite on the setscrews of the wheel collars

to prevent them from vibrating loose (figure 6).

4. Install the landing gear to the fuselage using the four 8/32 x /

bolts, spring washers, and flat washers. Loc-tite here is

recommended (figure7).

Tip#1Finish the end of the axle with 3mm of extra fuel tubing as added protection of wheel loss if collar

loosens during operation.

1. Use a Dremel or suitable device and

trim the center wheel opening on the

wheel pants on the side with the wood-

mounting block. Trim the center of the

wheel pants to fit the axle heads using

the wood block as guide (figure 8 and

9).

2. Raise the rear of the fuselage until the

model is level and block it in place. You

can use the cowling to block the fuselage

in a level position (figure 10).

3. Hold one wheel pant in place while

keeping the bottom of the wheel opening

level with your work surface and mark

your hole locations through the

mounting holes in the landing gear.

Repeat this step for the other side

(figure 11).

4. Drill the holes for the 4/40 bolts in the

wheel pants at the locations you ve

marked.

5. Apply some white wood glue to the

inner side of the four 4/40 blind nuts and

install the blind nuts to the inside of the

wheel pants (figure 14 and 15).

6. Mount the wheel pants to the landing

gear using four 4/40 x / bolts with

spring and flat washers. Use loc-tite on

these bolts, they are prone to severe

vibration (figure 16 and 17).

Tail wheelassembly andmounting:

What you will need for the tail wheel assembly and tiller:

Carbon fiber tail wheel bracket with packaged

hardware

Onemetal tillerassembly

Fuselageand rudder

Not Provided:

Across tipscrewdriver (Phillips)

One small Allen wrench for thewheel collars

Blueloc-tite

Adrill and a small pilot drill bit

7. Install tail wheel to the bracket using one washer on each side of

the brass bushing and install the small wheel collar. Use blue Loc-

tite on the setscrew of the wheel collars(figure 18).

8. Place a piece of low tack masking tape over the tail wheel bracket-

mounting block. Mark the centerline over the tape on the tail wheel

bracket-mounting block (figure 19).

9. Place the tail wheel bracket on the mounting block ensuring the

bracket holes line up with the centerline and mark the hole locations for the two large wood screws

(figure 20).

10. Once your locations are marked, drill two small pilot holes for the wood screws(figure 21).

11. Mount the tail wheel-bracket to the fuselage usingthe two large wood screws. Remove the bracket

and coat the threads created in the wood-mounting block with thin CAand re-assemble (figure 22, 23,

and 24).

12. Install the steel tiller horn just behind the hinge line on the bottom of the rudder using the two small

wood screws (figure 25, 26, and 27).

Set aside your two tiller springs, we will install those later after the rudder is mounted.

Chapter4

CanopyHatchand Cowling

Place an to ensure task completion:

Gather the following for canopy and hatch installation:

Canopy

FuselageandAccess Hatch

12small woodscrews

Two 4/40bolts withspring andflat washers

Cowling 3

Four6/32 x / bolts withspring andflat washers

Not Provided:

/2inch low tack masking tape

Drilland smalldrill bitfor woodscrews

Canopyglue(iptional)

1. Install the hatch on the fuselage using four 4/40 bolts with spring

and flat washers provided (figure28).

2. Trial fit the canopy to the fuselage access hatch to determine screw

locations.

3. Mark evenly spaced locations for the screws using at least six per

side. Also mark three evenly space locations around the front of the

canopy. Doublc chcck to cnsurc all thc marked scrcw locations will

go into the center of the hatch rail (figure29).

4. Remove canopy from the access hatch and drill the marked

locations for the canopy screws.

5. Install the canopy using the small wood screws.If satisfied with the fit,remove the canopy and hatch

and wick a small amount of thin CAinto each of the screws holes on the hatch.Once dried, reinstall

canopy with optional canopy glue if desired.Caution! CA will fog the canopy if installedbefore

completely drying (figure 30, 31, and 32).

6. Test fit and install the Canopy Hatch on the fuselage using the

four 4/40 x / bolts with spring and flat washers provided.If

satisfied,remove and set aside hatch for cowling installation

(figure 33).

7. For the cowling,drill two holes in the bottom for the two 6/32 x /2bolts from inside the cowling

using the cowl ring holes as a guide.(figure 29).

8. Install the comling using the four 6/32 x /2bolts ,spring washers, and flat washers. If satisfied with

the fit, remove the cowling and set aside for firewall and engine installation(figure 30 and 31).

Place an to ensure task completion:

Chapter 5

Engine and Firewall Installation

Your firewall is not pre-mounted so ourcustomers can select from a wide varietyof engine choices. It is nearly

impossible to cover every engine installation choicein this manual but we ll cover a few. Your Extra330L was

designed around the more popular lightweight gas(3 to 3 /2lbs) 50cc size motors.Also, we have provided a

canister tunnel on our Extra330Lfor those desire quieter operation. Pleaseconsult the manufacturer for the

installation of optional canister.

Wewill cover the installation of twopopular engine choices in this manual,the BME and the DA50cc motors.

Follow your engine manufactures instructions forany additional guidance. Lets get started!

What you will need in thischapter:

Firewall andFuse

Trianglestock includedwith thekit

Not Provided:

30 to45 minuteepoxy

An enginein therecommend sizerange

inch spinner

Propeller

Adrill anddrill bits

Center punch

A12 square

/2inch tape for DA-50 template

White wood glue such as Elmer for BME 50

With the engine is installed,you will want approximately 6 -13/16 inchesfrom the firewall to the spinner back

plate for proper cowl placement. DA-50 users using 3-inch standoffs should provideperfect clearance. Right

thrust has already been built into this design so that no additional measurements will be required.

1. First we ll need to lightly sand off the fuelproofing from the inside of the motor box wherethe

firewall will mount. Take 150 grit sandpaper and sand just where you will mount the firewalland

triangle stock (figure 37).

2. Glue in the top former of the motorbox using epoxy or medium CA(figure 38and 39).

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