3DHS Extra 330-E Assembly Manual

Text of 3DHS Extra 330-E User Guide:

• 3DHS Extra 330-E, 2 Please take a few moments to read this instruction manual before beginning assembly. We have outlined a fast, clear and easy method to assemble this aircraft and familiarizing yourself with this process will aid in a quick, easy build. Please read the following paragraph before beginning assembly of your aircraft! THIS IS NOT A TOY! Serious injury, destruction of property, or even death may result from the misuse of this product. Extreme Flight is providing you, the consumer, with a very high quali

• 3DHS Extra 330-E, 3 Extreme Flight designers Ben Fisher and Chris Hinson have long shared a mutual dream to bring to market a Giant Scale airframe purpose designed for electric power. Discussions and brainstorming sessions began even before the merger of Extreme Flight and 3DHS. With the development, release and overwhelming enthusiasm for the Xpwr line of motors and in particular the Xpwr 60, this vanity project has now become reality! Extreme Flight is proud to present the 3DHS 95" EXTRA 330E! The EXTRA 330E is a beautiful synergy of advanced composite materials implementation, extreme weight reduction measures and well i

• 3DHS Extra 330-E, 4 Items needed for completion: ✓ Masking tape ✓ Hobby knife with #11 blades ✓ Thin and medium CA. We highly recommend Mercury M5T thin and M100XF medium formulas as well as the Mercury glue tips ✓ 30 minute epoxy. Pacer Z-Poxy is a long time favorite ✓ Goop Silicon glue ✓ Blue and Red Loctite ✓ Electric drill with an assortment of small drill bits ✓ Small flat head and Phillips head screw drivers ✓ Standard and needle nose pliers ✓ Side cutters ✓ Metric ball driver or allen key set ✓ Sanding block and sandpa

• 3DHS Extra 330-E, 5 Tips for Success: 1. Before starting assembly, take a few minutes to read the entire instruction manual to familiarize yourself with the assembly process. 2. Go over all the seams on the aircraft with a covering iron on a medium heat setting. Also, due to climate changes, wrinkles may develop in the covering. These are easily removed with a little bit of heat. Use a 100% cotton tee-shirt and your heat gun and heat the covering while gently rubbing the covering onto the wood with the t-shirt. Be careful not to use too much heat as the covering may shrink too much and begin to lift at the edges. Take your time, and a beautiful, paint-like finish is attainable.

• 3DHS Extra 330-E, 6 Let's begin! Elevator Assembly 1. Locate the horizontal stabilizer/elevator assemblies as well as the composite control horns and base plates from the elevator hardware package. Trial fit the assembly into the slots in the elevator. 2. Trace around the base plate with a felt tipped marker.

• 3DHS Extra 330-E, 7 3. Remove the horn assembly and use a #11 blade to remove the covering from inside the ink line you traced around the control horn base. 4. Wipe away the ink line with a cotton cloth or paper towel soaked in denatured alcohol.

• 3DHS Extra 330-E, 8 5. Use sandpaper to scuff the portion of the horns and base plate that will be inserted into the elevator. 6. Apply 30 minute epoxy to the elevator slots using a zip tie to ensure the slots are filled will epoxy.

• 3DHS Extra 330-E, 9 7. Apply a generous amount of epoxy to the bottom of the G-10 control horns and base plate. 8. Reinsert the assembly into the elevator and wipe away any excess epoxy with a cloth and denatured alcohol. Place a 3mm bolt through the horns to help insure proper alignment and set aside to dry. Repeat for the other elevator half.

• 3DHS Extra 330-E, 10 Note: There are several methods and adhesives that can be used for installing the hinges. We will describe the way we do it as this method has proven itself over many years of model building. 9. Mix a generous batch of 30 minute epoxy. Use a zip tie or an old pushrod to thoroughly coat and fill the hinge holes on the stab with epoxy. 10. Next, coat one side of the hinges with epoxy and push the hinges into the holes of the horizontal stab.

• 3DHS Extra 330-E, 11 11. Make sure the hinge pins are centered in the hinge gap and that they pivot 90 degrees to the stab. 12. Now coat the other side of the hinges as well as the hinge holes in the elevator with epoxy and install the elevator onto the stab. Don’t forget to apply epoxy in the hinge holes on the stab before installing the stab to the elevator.

• 3DHS Extra 330-E, 12 13. Use denatured alcohol and a cloth to remove all excess epoxy, especially on the hinge pin. Make sure you have full deflection in both directions – once satisfied with the results, set the surface aside to dry. After the hinges have dried thoroughly, pull on the surfaces to make sure they are properly secured. Note: Before installing the servos, it’s a good time to seal the hinge gap with a strip of Ultracote or Blenderm tape. Also, I recommend that you dilute a small amount of epoxy with a few drops of alcohol and apply a light coat to the inside of the stab a

• 3DHS Extra 330-E, 13 14. Before installing the elevator servos, temporarily install the servo arms and electronically center the servos. Using the manufacturer supplied mounting hardware, install the elevator servo with the output shaft toward the rear of the stab and re-attach the servo arm. 15. Assemble the linkage and install as shown in the picture, using an Extreme Flight 2 inch servo arm and the provided 3mm hardware.

• 3DHS Extra 330-E, 14 Wing Assembly 16. Locate the wing/aileron assemblies as well as the composite control horns and base plates from the wing hardware package. Following the same procedure as outlined with the elevator/stabs, install the control horns and hinges for both wings. 17. Attach a 12 inch EF 20 awg servo extension to the aileron servo lead and secure with a servo safety clip or heat shrink tubing. Install the aileron servo using the manufacturer provided hardware with the output shaft oriented toward the lea

• 3DHS Extra 330-E, 15 Note: Before moving to the next step – it would be a good time to seal the hinge gaps with a strip of Ultracote or Blenderm tape. Be sure to fully deflect the control surface when sealing the gap to allow for full deflection once the gap is sealed. Also, take a few minutes to go over the wings with a trim iron on a medium heat setting to seal all the trim seams and remove any wrinkles in the covering. Use caution and avoid excessive heat as this may caus

• 16 19. Trail fit the landing gear fairings and when satisfied with fit secure with Goop style silicon glue. Tape in position until dry. 20. Locate the 2 axles, 2 locking nuts, 2 washers, 2 wheels, 4 wheel collars and 2 wheel pants. Place the threaded portion of the axle through the hole in the landing gear, place a washer onto the axle and secure the axle with a locking

• 3DHS Extra 330-E, 18 23. There are laser scribed marks for drilling for the motor mounting bolts for the Xpwr 60. Drill to accommodate 6mm bolts. If using another make of electric motor get the mounting template from the manufacturer and align on the laser inscribed crosshairs on the front of the motorbox. 24. We highly recommend using the Blazing Star XXL Standoff Set to easily and accurately mount your Xpwr motor to the Extra airframe. All necessary mounting bolts are provided in the standoff package.

• 3DHS Extra 330-E, 19 25. There is a dedicated location with pre-installed blind nuts for mounting our recommended ESC, the Castle Creations Edge 160HV. Simply bolt it in place with 3mm bolts. Remember the Loctite! 26. Take a few minutes to secure the motor wires, battery leads and receiver lead and tidy up the installation to prevent chafing.

• 3DHS Extra 330-E, 20 27. Locate the rudder, the rudder control horns and the 2 slotted base plates. Use sandpaper to scuff the bottom of the control horns as well as the side of the base plates that will attach to the rudder. If using a direct drive push-pull linkage (which is our recommended setup) only glue one set of horns in place on the right side of the rudder (pilot's perspective) in the lower position using the same procedure as you did with the elevators and ailerons. 28. As mentioned there are two locations available to install the rudder control horns. If using the pull-pull system use the upper horn locat

• 3DHS Extra 330-E, 21 There is a plywood jig included in the hardware package to help properly align the dual control horns if using a pull-pull setup. This makes achieving correct alignment a breeze. 29. Once your control horn installation has cured, mount the rudder to the fuselage using the same process as you did when gluing on the ailerons and elevators. 30. Locate the 2mm ball link from the tailwheel hardware bag. Drill a hole to accept the shaft of the ball link and secure it with epoxy. Once dry mount the tailwheel assembly as shown.

• 3DHS Extra 330-E, 22 31. Attach a 36" EF 20awg servo extension to your rudder servo and secure with an EF Servo Safety Clip. Install the rudder servo in the rear of the fuselage as shown if using a direct drive rudder actuation setup and assemble the linkage as shown with the provided hardware. 32. If using a pull-pull setup now is the time to install the pull-pull rudder cables. Install the cable onto the brass threaded connector as shown, using the aluminum crimp tube to secure.

• 23 33. Install the rudder servo in the designated location in the rudder tray. Electronically center the servo and install the EF 4" pull-pull arm. Secure the cables to the arm as show using 3mm bolts. As you'll notice in this picture we used the SWB Pull-Pull Tensioning Kit which makes getting the proper tension on the cables

• 3DHS Extra 330-E, 24 35. The cowl has a unique method of mounting that allows easy installation and removal. It is secured with 3 3mm bolts, 2 on the lower external portion of the cowl and one mounted from the interior of the fuselage. The cowl hangs on 2 hooks and is secured at these 3 locations. I chose to use 2 of the EF Thumb Screws for the exterior mounting and spray painted them to match the paint on the cowl.

• 3DHS Extra 330-E, 25 36. Attach a 36 inch EF 20 awg servo extension to each elevator servo lead. If you plan to remove the stabs for transport, you will need to use 48 inch extensions. Secure with EF Servo Safety Clips or heat shrink tubing. Slide the stab halves onto the carbon fiber stab tube and secure with a 3mm bolt and washer inserted through the mounting tabs and into the pre-mounted blind nuts. Make sure to use a drop of blue Loctite on these bolts. 37. The wings are mounted on

• 26 39. There is plenty of room inside the fuselage to secure all of your servo extensions and battery wires. Take a few minutes and tidy up your installation and make sure everything is secure and protected from chafing. Here is a picture of the interior of our Extra to show how we secured the internals. Set-up and trimming Besides basic assembly, this is the mo

• 3DHS Extra 330-E, 27 Control surface throws I highly recommend that you purchase a throw meter that measures in degrees. There are several units available commercially. These units are a great aid in set-up and definitely beat the “that looks about right” method. For any type of precision flying, surfaces that travel equal distances are a must. The following control surface travels are what I use on my own Extra. These are a good starting point, but are by no means the only way to set up the Extra. Start here and then adjust to fit your own preferences and style

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