Contact Us

AirWild Hobbies
23172 Alcalde Drive, Unit B
Laguna Hills, CA 92653
U. S. A.
(949)699-1059
WWW.AIRWILDHOBBIES.COM
info@airwildhobbies.com

This product is sold with exclusion of all warranty expressed or implied, statutory or
otherwise. Buyer assumes all risks of use.

INTENDED USE

The Extra 260 kit is precisely crafted to produce an airplane that is capable of winning at the
highest levels of precision aerobatic competition. It should only be flown by radio control pilots
experienced with this type of high performance, mid wing airplane at flying sites that comply
with the standards set by the Academy of Model Aeronautics or other nationally recognized
radio control sanctioned organizations.

WARRANTY

AirWild will repair or replace individual parts, or all, of the kit for defects in material and / or
manufacturing for a period of thirty (30) days from invoicing. There are no exceptions.

ABOUT THIS ASSEMBLY MANUAL

This manual divides the assembly into several sub-assemblies; fuselage, stabilizer, wing,
rudder, landing gear, etc. Please read each section carefully and familiarize yourself with each
step before starting on the particular sub-assembly. Photos and illustrations are provided in
this manual to clarify and detail many sub-assembly steps. The two should be used together to
facilitate your assembling.

AIRPLANE SPECIFICATIONS:

Wing Span: 87 in. (2210 mm)

Fuse Length: 78 in. (1981 mm)
Wing Area: 1370.5 sq. in. (0.9 sq. m.)

ULTRACOTE SPECIFICATIONS:

COLOR MANUFACTURER PART NUMBER DESCRIPTION

White Hanger 9 HANU870 White
Red Hanger 9 HANU866 True Red
Yellow Hanger 9 HANU1884 Cub Yellow
Silver Hanger 9 HANU881 Silver
Purple Hanger 9 HANU847 Pearl Purple

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 2
PACKING LIST:

This list is provided for your convenience. Before starting on putting the airplane together, go
through your kit and verify that all parts are present and in good condition. Contact AirWild
Hobbies at (949)699-1059 for any discrepancies.

Item # ; Description Qty

1 ˆ Fuselage 1
2 ˆ Canopy Hatch 1
3 ˆ Canopy 1
4 ˆ Wing, Left 1
5 ˆ Wing, Right 1
6 ˆ Aileron, Left 1
7 ˆ Aileron, Right 1
8 ˆ Wing Tube, Aluminum, O.D. ∅ 25 MM x 790 MM 1
9 ˆ Stabilizer, Left 1
10 ˆ Stabilizer, Right 1
11 ˆ Stabilizer Tube, Aluminum, O.D. ∅ 10 MM x 320 MM 1
12 ˆ Elevator, Left 1
13 ˆ Elevator, Right 1
14 ˆ Rudder 1
15 ˆ Aluminum Main Landing Gear 1
16 ˆ Fiberglass Cowl 1
17 ˆ Fiberglass Wheel Pants 2
18 ˆ Socket Head Cap Screw, Stainless Steel, M4x20 6
19 ˆ Socket Head Cap Screw, Stainless Steel, M3x15 14
20 ˆ Blind Nut, Stainless Steel, M3 4
21 ˆ Flat Washer, Stainless Steel, M3 16
22 ˆ Flat Washer, Stainless Steel, M4 6
23 ˆ Pan Head Wood Screw, 3MMx15MM 2
24 ˆ EFP Control Horn 10
25 ˆ Tail Wheel Bracket 1
26 ˆ CA Hinge 21
27 ˆ Assembly Manual 1

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 3
To some of you setting up an airplane of this size may be a first-time experience and can be
confusing. So we thought to provide you a list of items that we personally used to complete our
own prototype airplanes. Hopefully this may serve as a starting point in your quest for the
perfect setup.

Suggested Component List

Functional Description Qty. Mfgr. Mfg. P/N

Group
Wheel Axles, 5/32''x2'" (2/Pk) 1 DuBro DUB248
Wheel Collars, 5/32" (4/Pk) 1 DuBro DUB140
Landing Gear
& SkyLite Main Wheel, 3" (2/Pk) 1 Sullivan SUL877
Tail Wheel Tail Wheel, 1” 1 DuBro DUB100TW
Wheel Collars, 3/32” (4/Pk) 1 DuBro DUB138
EFP Control Horn 2 AirWild AW61-112-02
MLP Aluminum Servo Arm, 3” 1 AirWild
Cable Attach Fitting (4/Pk) 1 AirWild AW60-090-01
Pull-Pull Cable, 60 lbs. 1 AirWild 60WNA
Rudder
4-40 Safety Lock Kwik-Link (2/Pk) 1 DuBro DUB817
Ball Link, 1/4 HD Ball (2/Pk) 1 DuBro DUB899
High-Torque Digital Metal Gear Servo, 150 oz. 1
In. (recommended)
EFP Control Horn 4 AirWild AW61-112-02
MLP Aluminum Servo Arms, Half, 1.25" 2 AirWild
Ball Link, 1/4 HD Ball (2/Pk) 2 DuBro DUB899
Elevators #4-40 Threaded-End Carbon Fiber Push Rod 2 AirWild AW60-200-01
Twist'd Servo Extensions, 18” 2 AirWild AW80-064-01
High-Torque Digital Metal Gear Servo, 120 oz. 2
In. (recommended)
Titanium Pro-Link, 1.5" (2/Pk) 1 Hanger 9 HAN3550
MLP Aluminum Servo Arms, Half, 1.0" 2 AirWild
Ailerons Twist'd Servo Extensions, 6” (Ailerons) 2 AirWild AW80-060-01
EFP Control Horn 4 AirWild AW61-112-02
Ball Link, 1/4 HD Ball (2/Pk) 2 AirWild DUB899
High-Torque Metal Gear Digital Servo, 120 oz. 2
In. (recommended)
Fuel Tank, 20 oz. 1 Du-Bro DUB420
Fuel Tubing 1 Aerotrend AER1073
Fuel Filler w/ T Coupler 1 Hanger 9 HAN115
Fueling & Fuel Filter 1 Dynamiite DYN2006
Engine
Ignition Carbon Fiber Push Rod, Semi Flex (throttle 1 Sullivan SUL580
push rod)
Universal Ball Joint, 2-56 Threaded 2 DuBro DUB181
Mini Digital Metal Gear Servo, 60 oz. In. 1
(recommended)

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 4
 HD On/Off Switches, Ignition 1 Cermark DSC Switch
Optical Kill Switch, Ignition 1 SmartFly SFIC
NiMH 6V/1650mA, Ignition Battery 1 Cermark NIMH6V1650
50 cc. Gasoline engine, DA-50R 1 DA DA50-R
Muffler, DA50-R 1 DA DA50-R Muffler
Extra-Style 4” Spinner, DA50 Back Plate 1 AirWild AW92-400-02D50
NX 22x8 2-blade Prop (Break-in Use) 1 AirWild AW200-2208-02
NX 23x8 2-blade Prop (Normal Use) 1 AirWild AW200-2308-02
Receiver, 7 Channels (minimum), PCM 1
Receiver
Twist'd Servo Extensions, 6” (Ailerons) 2 AirWild AW80-060-01
Electronics
NiMH 6V/1650mA Battery Pack 1 Cermark NIMH6V1650
HD On/Off Switch, RX Battery 1 Cermark DSC Switch
Velcro Strips (Misc. amount)
Accessories WingPAK Pro-Series, 30% 1 AirWild AW80-110-01

• This list contains items that we believe offering the highest quality and reliability for our
particular application. Nevertheless please do not feel restricted to such selections as
many other comparable options are available on the market.

• AirWild Hobbies in no way warrants these products on behalf of the original

manufacturers. All warranty related issue should be addressed with the manufacturer
directly.
Disclaimer:

This list is provided only as a reference. AirWild Hobbies, Inc. does not in any fashion guarantee nor
assumes product liabilities of their uses by customers. Please consult your local hobby shops or contact
manufacturers directly for specific information. Buyer assumes all risks of use.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 5
For your convenience we have also put together two very complete hardware packages, each
consists of high-quality, name-brand products. To purchase these packages please contact
AirWild Hobbies directly.

This hardware package is provided as a convenience to end users. AirWild Hobbies, Inc. does not in any
fashion guarantee nor assumes product liabilities of their uses by customers. Buyer assumes all risks of
use.

AirWild 29% Extra 260 Hardware Package (AW80−204−01−F/H/J)

Functional Description Qty. Mfgr. Mfg. P/N
Group
Wheel Axles, 5/32''x2'" (2/Pk) 1 DuBro DUB248
Landing
Wheel Collars, 5/32" (4/Pk) 1 DuBro DUB140
Gear &
Tail Wheel SkyLite Main Wheel, 3" (2/Pk) 1 Sullivan SUL877
Tail Wheel, 1” 1 DuBro DUB100TW
Wheel Collars, 3/32” (4/Pk) 1 DuBro DUB138
MLP Aluminum Servo Arm, 3” (Specify Servo) 1 AirWild TBD
Rudder
Cable Attach Fitting (4/Pk) 1 AirWild AW60-090-01
Pull-Pull Cable, 60 lbs. 1 AirWild 60WN
4-40 Safety Lock Kwik-Link (2/Pk) 1 DuBro DUB817
Ball Link, 1/4 HD Ball (2/Pk) 1 DuBro DUB899
MLP Aluminum Servo Arm, 1.25"(Specify Servo) 2 AirWild TBD
Elevators
Ball Link, 1/4 HD Ball (2/Pk) 2 DuBro DUB899
#4-40 Threaded-End Carbon Fiber Push Rod 2 AirWild AW60-200-01
Twist'd Servo Extensions, 18” 2 AirWild AW80-064-01
Titanium Pro-Link, 1.5" (2/Pk) 1 Hanger 9 HAN3550
Ailerons
MLP Aluminum Servo Arm, 1" (Specify Servo) 2 AirWild TBD
Twist'd Servo Extensions, 6” (Ailerons) 2 AirWild AW80-060-01
Ball Link, 1/4 HD Ball (2/Pk) 2 AirWild DUB899
Fuel Tank, 20 oz. 1 Du-Bro DUB420
Fueling
Gas Stopper Conversion Kit 1 Du-Bro DUB400
Fuel Tubing 1 Aerotrend AER1073
Fuel Filler w/ T Coupler 1 Hanger 9 HAN115
Fuel Filter 1 Dynamite DYN2006
Receiver Twist'd Servo Extensions, 6” (Ailerons) 2 AirWild AW80-060-01

Recommended Extra 260 Electronics Package (AW80−205−01−F/J)

Functional Description Qty. Mfgr. Mfg. P/N
Group
Optical Kill Switch, Ignition 1 SmartFly SFIC
NiMH 6V/1650mA (Ignition) 1 Cermark NIMH6V1650
Ignition
DSC HD On/Off Switches, Ignition 1 Cermark DSC Switch
(Specify JR or Futaba type)
DSC HD On/Off Switches, RX 1 Cermark DSC Switch
RX (Specify JR or Futaba type)
NiMH 6V/1650mA (Ignition) 1 Cermark NIMH6V1650

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 6
PREPARING FUSELAGE FOR ASSEMBLING:

Remove fuselage from the shipping box and place it on a flat working surface. Refer to the
following illustration to familiarize yourself with various key features of the fuselage before
attempting to assembly the airplane. A good preparation goes a long way.

E N G I N E M O U N T IN G :
; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Cowl 1
ˆ Spinner, 4 in., Extra (option) 1 ˆ Engine (option) 1

Since there are many excellent choices of engines for this airplane, we can only provide a basic
reference for a typical installation. Use the following dimensional drawings in conjunction with
your engine’s outline specifications to determine the proper setup necessary for your particular
engine. Please carefully review all dimensions before proceeding.

For DA50-R users, we have prepared a very comprehensive guide on installing DA50-R in a
later section. Familiarize yourself with the general guide before skipping to the DA50-R section.

Warning:
Under no circumstances never disassemble, cut into, nor break up engine box structure to
adapt for your particular engine. Failure to comply will void manufacturer warranty.

Dimensional References – Engine Installation

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 7
The following procedures is a non-brand specific guide to install your particular engine. This by
no means is the ONLY way NOR does it apply to all engines across the board. This is simply
one user’s general approach, written for you information only.

General Guideline for Installation of Radial-Mount Engine:

1. Determine the full length of your engine, from

base of engine mount to the prop hub. Let’s call
this dimension X. For the purpose of discussion
we use DA50-R’s dimension for illustration.

2. Now refer to the “dimensional reference – engine

installation” in the previous section, take the
Diagonal Distance (170.25 mm) and subtract X
from it.

Y = 170.25mm – X

3. Dimension Y is the thickness of spacer you need to fabricate to position the engine for the
proper clearance. Use a 3/4” ~ 1” wooden dowel which you can easily find at your local
hardware supply, ie. Home Depot, and then cut to length.

STAND-OFF FABRICATION
Cut dowel to the desired length. Make sure they are all of even length. Use a drill press to do the next step.
Drill a center hole of the appropriate diameter for the engine mounting bolt to run through the dowel. Next,
saturate the through hole and two ends of the dowel with thin CA. Harden with CA Kicker. This will
prevent the dowel from splitting under pressure. Repeat same steps to fabricate the remaining pieces.

4. Next you need to locate and drill the mounting pattern for your radial-mount engine. A set
of offset center lines has been laser scored onto the front of firewall. Refer to your engine
manual in conjunction with the center line references to locate the bolt pattern. Drill and
mount your engine accordingly.

DA50-R Engine Installation Guide

1. Make sure your DA aluminum stand-offs is the standard-size, 2.5” set.

2. Fabricate four (4) 0.25” (6.35mm) thick spacers out of 5-layer, 0.25” thick plywood.
3. Install spacer between stand-off and fire wall.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 8
For your convenience we have created a sheet of DA50-R mounting bolt pattern template to
simplify your work. Simply cut out the template, superimpose it onto the firewall and locate the
mounting holes that way.

Mounting Holes Located & Drilled DA Standoffs Installed DA50-R Installed

(0.25” plywood spacers not shown) (0.25” plywood spacers not shown)

Installing the DA ignition module is the next thing to do. The ideal place for ignition module is
on the bottom surface of the engine box, as shown in the illustration below

DA50-R Ignition Installation Guide

1. Turn the airplane upside down to have the bottom of the

engine box facing up.

2. Place ignition module in the middle of the surface. Mark

and cut two slots to be used for strapping down the ignition
module. We prefer using Velcro strip to for this application.

3. Apply thin CA to the perimeter of the slot. This will reduce

chances of plywood splitting. Harden with CA Kicker.

4. Use Velcro strip to secure ignition module as illustrated.

Cushion the module with a piece of foam.

5. Drill a hole through the bottom surface to route the battery

connector of the ignition module to the inside of the engine
box where the ignition battery will situate.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 9
The block diagram below illustrates how we completed the rest of the ignition power distribution
setup. Refer to our “Suggested Component List” for the specifics on individual components.

6. Your ignition battery can be strapped down using the same

Velcro strip or you can use a second Velcro strip to secure
the ignition battery. Make sure to also cushion the ignition
battery pack.

7. Cutout for the ignition battery switch has been precut and is
located in front of former #2 as illustrated. Cutout is
dimensioned to fit a DSC Super Switch. Cut away Ultracote
to reveal cutout and mount switch accordingly.

8. An optical ignition kill switch is not required but highly

recommended for safety as it allows you to remotely turn off
engine in case of emergency, not to mention the fact that it
is also a convenience. Our preferred device is the SmartFly
Optical Kill Switch as it is extremely compact and proven
over the years to be very reliable, and also offers a
detachable and highly visible LED for status display of
ignition power.

Before mounting the optical kill switch you do have to make one modification; change
SmartFly Optical Kill Switch’s ignition side connector from a standard 3A rated servo
connector to a 10A-rating Anderson Power Poles (APP) connector provided in your
DA50-R ignition package. Unfortunately this is inevitable as there is no set standard for
interconnecting engine related devices in the RC hobby industry. Get your soldering iron out.
Find some heat shrink tubing and get started. Refer to photos below for BEFORE and AFTER.

Mount optical kill switch with a Stock SmartFly optical kill switch Modified SmartFly optical kills
double-sided foam tape. shown with a servo-type connector switch with an APP connector for
for ignition. DA50 ignition.

When done, find a spot to mount your SmartFly optical ignition kill switch. Use adhesive back
foam tape or Velcro tapes to secure it. You are done with this part of installation.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 10
M O U N TI N G FU E L T A N K :
; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Fuel Tank (20 oz.) (option) 1
ˆ Double Sided Velcro Strips (option)

By design fuel tank is located

on CG of the airplane. We
have designed in a plywood
fuel tank tray as illustrated in
the photo.

Set up the internal plumbing of your tank first. When ready, simply strap in your fuel tank to
the tank tray with two pieces of double-sided Velcro strip. Please note that there are two cross
members running length wise under the fuel tank tray for support. Be sure to route your Velcro
strips under the cross members. As a good practice always cushion your fuel tank with a piece
of high density foam; preferably on both top and bottom of the tank.

We also highly recommend using stainless steel twist ties to secure fuel line to copper tubing.
This will provide added security in preventing fuel line from slipping off copper tubing in hot
environment. Sullivan Product’s Twist-Tie Clamps (P/N #488) is a great choice for this
application which is available from AirWild Hobbies / AirWild Pilot Shop online.

Basic Setup of Fuel Delivery System

Most gasoline engines are equipped with a suction based

carburetor such as Walbro or Tilliston. Therefore your fuel tank
must be vented to provide one critical ingredient of this fuel
delivery system; atmospheric pressure. Illustration above
demonstrates a typical setup for fuel delivery.

Select gasoline compatible components to construct this basic

configuration. If you have purchased a hardware package from
AirWild, refer to the list below for component usage.

Fuel Tank „ 20-oz. tank with gasoline compatible stopper and internal Du-Bro
tubing DUB420
Fuel Tubing „ Gasoline compatible fuel tubing, cut to size Aerotrend
AER1073
Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 11
 Fuel Filler w/ T „ Package contains inlet with plug (for fueling) and T-coupler. Hanger 9
Coupler „ Use the same inlet for gassing up and defueling. HAN115
Fuel Filter „ Extremely critical to have a good inline filter to engine Dynamite
carburetor. Prefer one with removable filter screen DYN2006
„ Adding an optional inlet filter to prevent contaminants from
entering fuel system. Highly recommended
Fuel Vent „ Simply run this fuel line out through the bottom of fuselage
„ Drill a hole in main landing gear plate to accomplish this

Throttle Servo Setup

Our preferred choice of throttle servo is a mini metal gear digital servo. It offers compact
footprint, light weight, good holding power and, most importantly, accurate movement to always
assure the most precise throttle setting.

Depending on the engine brand the engine throttle arm can situate either on the left or right
side of engine carburetor. To address this discrepancy our Extra 260 design allows you to
place throttle servo on the side of the throttle arm by using glue-in plywood mounting rails to
anchor the servo. Make frequent references to photos and illustration to complete the following
steps.

1. A plywood mounting rail consists of gluing two pieces of

45mm x 15mm x 2mm plywood together. You will find
provided in the kit four pieces of such plywood to make two
rails.

2. Once you have determined which side to install the throttle

servo, glue one mounting rail to the corner of the former
cutout using thin CA.

3. Position throttle servo so that one mounting flange rests on

the plywood mounting rail and slide the second rail under to
match up with the other mounting flange of the servo.

4. Glue the second rail in place. Since this rail is partially

suspended, use epoxy to glue it. When epoxy is completely
cured remount throttle servo.

5. Use Sullivan #580 CF push rod kit to fabricate throttle push rod. Cut both inner CF push
rod and outer housing to length. We recommend DuBro #181, Universal Ball Joint, for
end-point attachment to both throttle servo arm and engine throttle arm.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 12
COWL ATTACHMENT:
; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Cowl 1
ˆ Spinner, 4 in. (option) 1 ˆ Engine (option) 1
ˆ Cowl Mounting Plywood Kit 1 ˆ SHCS, M3 4
ˆ Washer M3 4 ˆ Blind Nut, M3 4

1. From the front edge of the fuselage side measure

33.5mm to its right. Draw a parallel line. Place a piece of
masking tape at where you intend to draw and then mark
your line on the masking tape. This will protect Ultracote
from being marred. Let’s call this line “Cowl Reference
Line”. Repeat this for the other side of fuselage.

2. Slide on cowl to the marked lines. Next, put the spinner

back plate onto the prop shaft and push it all the way up
against the prop hub. Check to see if you are satisfied
with the gap between spinner back plate and cowl.
Reposition cowl if necessary to obtain the desired gap
width.

The cowl overlaps the fuselage front by 33.5mm as shown.

This setting allows for approximately 2mm wide of gap between
the spinner back plate and the front of the cowl. With that in
mind follow the procedures below to get it mounted. With
engine installed (no muffler) slide on the cowl to position.

4. Locate the bag of plywood mounting block kit that’s

provided in the kit. It contains eight (8) pieces of 20mm x
10.5mm x 2mm plywood pieces. You will need to glue two
pieces back to back to make four 20mm x 10.5mm x 4mm
mounting blocks.

5. Refer to photo and glue these mounting blocks to locations

shown with 5-minute epoxy.

6. When cured install M3 blind nut provide for each mounting

block. Center point of the blind nut is about 5mm from the
edge of the fuselage.

7. Transfer blind nut locations to cowl. Drill holes in cowl to

accept M3 socket head screw for securing the cowl.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 13
 MAIN LANDING GEAR:
; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Aluminum Landing Gear 1
ˆ Socket Head Cap Screw, M4x20 4 ˆ Flat Washer, M4 4

Place the fuselage up side down and locate the main landing
gear block. Note that four blind nuts for securing the main
landing gear have been pre-installed. Remove the main
landing gear from the shipping box and you will notice that it
also has a set of predrilled matching holes. Match up the hole
pattern and simply secure the main landing gear to the landing
gear block using four (4) M4 x 20 socket head cap screws and
washers.

WHEEL& WHEEL PANTS:

; Required Parts Qty. ; Required Parts Qty.
ˆ Aluminum Landing Gear 1 ˆ Axles, ∅5/32’‘ x 2’‘ (option) 2
ˆ Wheel Collars, ∅5/32’‘ (option) 4 ˆ Pan Head Wood Screw, 3MM 2
ˆ Washer, 3MM 2 ˆ Main Wheels, (3’‘ (option) 2
ˆ Wheel Pants 2

1. Install axles to the main landing gear.

2. Trial fit a 3” main wheel with a wheel pants. Enlarge the

wheel well cutout if necessary to assure unobstructed
rotation.

3. Position wheel, wheel collars and wheel pants onto axle.

Adjust wheel pants until you have obtained the correct
seating angle. Thread the provided 3mm Pan head wood
screw through the predrilled hole in the landing gear into the wheel pants plywood block.
This will pull the wheel pants up against the landing gear and lock it into position. You may
need to add a few washers to maintain proper spacing between the two.

TAIL WHEEL ASSEMBLY:

; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Tail Wheel Assembly 1
ˆ Tail Wheel, 1” (option) 1 ˆ Wheel Collar, 3/32” (option) 2

Since there is a large selection of tail wheel assemblies out

there, we will only discuss steps involved in installing our
preferred choice of tail wheel assembly, Sullivan Products’ Tail
Wheel Assembly, P/N# SUL861. Please use this information
as reference for mounting your choice of tail wheel assembly.

Mounting Sullivan Tail Wheel Assembly, P/N #861:

Follow instructions provided in the Sullivan Tail Wheel Assembly

package to mount it to the fuselage. For convenience you can
mount the assembly using two wood screws instead.

Doc. No.# AW70-105-01, Rev. 3 Copy Right 2006, AirWild Hobbies, Inc. Page 14
Install the steering spring according to the package instructions.

We’ve found that by adding a second anchoring point near the

coil spring will significantly improve the responsiveness of tail
wheel steering (see photo). As illustrated we used a piece of
scrap nylon strap and two sheet metal screws to accomplish this.

CLEAR CANOPY:
; Required Parts Qty. ; Required Parts Qty.
ˆ Canopy 1 ˆ Canopy Hatch 1

Canopy has been pre-trimmed to size. Simply position the

canopy over the hatch and align it to the recessed layout. Once
you are satisfied with the position, glue it to hatch cover with
adhesive such as RC56, Zap-A-Gap-A-Goo or Liquid Nail.
These types of adhesive give you ample time to work with
positioning the canopy, yet once hardened any excess can be
easily trimmed off with a sharp blade.

Hinging & Control Horn Installation

Please note that this airplane is designed to use the provided heavy duty CA hinges and
EFP Control Horns for all hinging and control horn setup. Do not vary from this
configuration as the internal structure is not intended to accommodate any other
schemes. Deviation from our designed configuration will void manufacturer warranty.

RUDDER HINGING & CONTROL HORN SETUP:

; Required Parts Qty. ; Required Parts Qty.
ˆ Fuselage 1 ˆ Rudder 1
ˆ CA Hinge 3 ˆ EFP Control Horn 2

Start with installation of the rudder control horns first as it is

easier to mount them prior to hinging the rudder.

Familiarize yourself with all the steps BEFORE proceeding.

1. Refer to photos on the right. Use your fingers to feel for a

13mm x 2mm slot covered under the white Ultracote
situated in the left low corner of the rudder. There is one
on each side of the rudder. These are slots for your left
and right rudder control horns.

2. Use a Xacto blade to puncture the covering material and

expose the slot. Slit the covering to the length of the slot.

3. Now use your Xactor blade and cut into the balsa core to
deepen the slot. Your goal is to create a through slot from
one side of the rudder to the other. Cut a little bit at a time
Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 15
 on each side and alternate side often. The cuts will
eventually meet in the middle of the balsa core and
complete the through slot. Remember to maintain the
cut perpendicular to the rudder surface

4. Trial fit the rudder horn into the slot for fitment. Loosen
slots (not length) if needed. Set up left and right rudder
horns according to the illustration below. You will need to
snip off approximately 4mm from the bottom of the horn in
order to get two horn to seat back to back.

5. Use a small amount of thin CA to tag glue the horns in place temporarily. This will allow
you to double check horn alignment before permanently sealing the horns. Break off tag-
glued joint if needed to realign horns.

6. When satisfied with horn alignment, glue both horns in place with thin CA. Saturate the
balsa core with thin CA and then harden it with CA Kicker. This step is very critical as it
dictates the bonding strength of the entire setup. If your slots are too loose, use gap-
filling medium CA to fill the voids.

Now we are ready to hinge rudder with the provided heavy-duty CA hinges. For this installation
we only require three (3) pieces of the CA hinges.

Draw CA hinge center line Install CA hinges Complete rudder hinging

7. Locate your CA hinges and draw a center line length wise on each CA hinge as shown.

8. CA hinge slots have all been precut for you in the rudder leading edge. Install all three
hinges up to the center line. Glue them in place with thin CA. Do not use CA Kicker for
this part of installation.

9. CA hinge slots have also been precut in the trailing edge of the vertical fin. Line up CA
hinges with the slots and slide rudder into place. Make sure that vertical fin and rudder are
budding against each other, thus eliminating any gap. Maintain a small gap between top of

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 16
 vertical fin and the rudder counter-balance. Pivot the rudder to make sure there is no
hindrance in movement. When satisfied attach rudder permanently with thin CA.

Rudder Servo & Pull-Pull Cables Installation

Rudder control employs the pull-pull configuration where servo

is mounted inside the fuselage and linked to rudder control
horns via two parallel cables. Make frequent references to the
provided photos to guide you through the installation.

Servo Type: metal gear, 140 oz. in. output torque minimal,
digital preferable.
Servo Arm: aluminum full arm, 3” length

1. Drop in rudder servo and orient it so that the servo output

shaft is closer to the wing tube socket.

2. Install servo arm. Orient servo arm at 90 degrees to servo

case. We recommend hooking up servo to your receiver
and turn on your transmitter and receiver while doing so.
The default neutral point of every servo depends entirely
on the internal potentiometers of the particular transmitter
in use. Orient the servo arm at closely to a right angle as
possible and then use transmitter’s Sub-Trim function to
dial it in.

3. Construct a pair of pull-pull cables. We recommend the

following components which are included in our optional
hardware package. Build up one end of the cable first.
Then route the unassembled end through the cable exit
slot first before assembling the open end.

„ Safety Lock Kwik-Link X2 DuBro #817

„ 1/4 HD Ball Link X2 DuBro #899
„ Cable Attachment Fitting X4 AirWild
AW60-090-01
„ Cable, Stainless Steel, Nylon AirWild
Coating, 60 lbs. Rated 60WN

4. Hook up cables in parallel, to rudder servo arm and rudder control horns. Adjust cable
tension accordingly by dialing available threads in the Cable Attachment Fitting till
adequate cable tension.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 17
ELEVATOR HINGING & CONTROL HORN SETUP:
; Required Parts Qty. ; Required Parts Qty.
ˆ Horizontal Stabilizer 2 ˆ Elevator 2
ˆ CA Hinge 8 ˆ 1/4 HD Ball Link (option) 1
ˆ #4-40 SHCS (part of ball link set) ˆ #4 Lock Nut (part of ball link set)

Familiarize yourself with all the steps BEFORE proceeding.

1. Locate all eight CA hinges and draw a center line length wise
on each as shown.

2. There are four CA hinges per elevator. Hinge slots have all
been precut in the leading edge of the elevator and the trailing
edge of the stabilizer.

3. Starting first with elevator install all four hinges up to the center
line. Glue them in place with thin CA. Do not use CA Kicker
for this part of installation.

4. Line up elevator and stabilizer and slide CA hinges into the

trailing edge of the stabilizer. Make sure that is no hinge gap
between them. Pivot elevator to make sure there is no
hindrance in movement. When satisfied attach elevator and
stabilizer together with thin CA.

Installing elevator control horns is very similar to that of the rudder

horn installation with the exception that it takes two (2) EFP control
horns to build one elevator control horn assembly.

5. Refer to the photo on the right, locate two (2) 13mm x 2mm
slots covered under the purple Ultracote. These are the slots
for the elevator control horn assembly.

6. Use a Xacto blade to puncture the covering material and

expose the slots. Slit the covering to the length of the slot.

7. Now use your Xactor blade and cut into

the balsa core to deepen the slot. Your SHORTEN EFP HORN ACCORDINLGY TO FIT
goal is to create a deep slot that position
control horn’s pivot hole 1.25” below the
elevator hinge line. Remember to
maintain the cut perpendicular to the
rudder surface. Complete one horn at a
time.
8. Trial fit both control horns into the slots
for fitment. You will have to shorten the
EFP horns accordingly. Enlarge width of
the slot (not length) if needed. Align
horns to match illustration on the right.
Do not tag glue them yet.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 18
9. Sandwich a 1/4 HD ball link between the two horns as
shown. Retain the ball link by threading the #4-40 SHCS
through both horns and ball link and lock in place with the
#4 lock nut. This keeps two horn parallel to each other and
creates a slop-free joint between control horns and ball link
which is critical to the precision of elevator movement.

10. Once again re-check horn alignment. When satisfied, glue

both horns in place with thin CA. Saturate the balsa core
with thin CA and then harden it with CA Kicker. This step
is very critical as it dictates the bonding strength of the entire setup. If your slots are
too loose, use gap-filling medium CA to fill the voids. When all is done, remove ball link.

11. Repeat 3~10 for the other stabilizer / elevator pair.

Elevator Servo & Push Rod Installation

Elevator servo slot has been

precut to accept standard-size
servo. Illustration on the right
demonstrates our intended
configuration. Refer to illustration
often as we proceed. Let’s work
on the right elevator first. Repeat
for the left elevator.

Servo Type: metal gear, 100 oz. in. output torque minimal, digital servo preferable
Servo Arm: aluminum half arm, 1.25” length

5. Drop in elevator servo and orient it so that the servo output shaft is closer to the elevator
leading edge.

6. You will need to attach an extension lead to the servo in order to route lead to receiver.
Exact length of the extension depends on your receiver placement. If you are following
AirWild’s default setup, now is the time to attach an 18” extension to the servo. Use a
piece of dental floss to secure the interconnect.

7. Construct elevator push rod. We recommend the following

components which are included in our optional hardware
package;

„ AirWild Carbon Fiber Push Rod x1 AirWild #AW60-200-01

„ 1/4 HD Ball Link x2 DuBro #899

8. Install servo arm. Orient servo arm at 90 degrees to servo

case. Hook up servo to receiver and turn on transmitter while performing this setup for
reason mentioned previously.

9. Hook up push rod to servo arm and EFP control horns. Adjust the turnbuckle push rod
until elevator is in neutral and servo arm is at 90 degrees to the servo body.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 19
AILERON HINGING & CONTROL HORNS SETUP:
; Required Parts Qty. ; Required Parts Qty
.
ˆ Wing Half 2 ˆ Aileron 2
ˆ CA Hinge 10 ˆ EFLPControl Horn 4
ˆ #4-40 SHCS (part of ball link set) 2 ˆ #4 Lock Nut (part of ball link set) 2
ˆ Thin CA ˆ Medium CA
ˆ CA Kicker

This part of installation will require us to first hinge the aileron, then install the aileron control
horns.

Familiarize yourself with all the steps BEFORE proceeding.

1. Locate ten (10) CA hinges and draw a center line length wise
on each as shown.

2. There are five (5) CA hinges per aileron and slots have all
been precut in the leading edge of the aileron and the trailing
edge of the wing.

3. Starting first with elevator install all five hinges up to the center
line. Glue them in place with thin CA. Do not use CA Kicker
for this part of installation.

4. Line up aileron and wing and slide CA hinges into the trailing
edge of the wing. Make sure that is no hinge gap between
them. Pivot aileron to make sure there is no hindrance in
movement. When satisfied attach aileron and wing together
with thin CA.

5. Refer to the photo on the right, locate two (2) 13mm x 2mm
slots covered under the purple Ultracote. These are the slots
for the aileron control horn assembly.

6. Use a Xacto blade to puncture the covering material and

expose the slots. Slit the covering to the length of the slot.

7. Now use your Xactor blade and cut into the balsa core to
deepen the slot. Your goal is to create a
deep slot that position control horn’s SHORTEN EFP HORN ACCORDINGLY
pivot hole 1.0” below the elevator hinge
line. Remember to maintain the cut
perpendicular to the rudder surface.
Complete one horn at a time.

8. Trial fit both control horns into the slots

for fitment. Enlarge width of the slot (not
length) if needed. Align horns to match
illustration on the right. Do not tag glue
them at this time.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 20
9. Sandwich a 1/4 HD ball link between the two horns as
shown. Retain the ball link by threading the #4-40 SHCS
through both horns and ball link and lock in place with the
#4 lock nut. This keeps two horn parallel to each other
and creates a slop-free joint between control horns and
ball link which is critical to the precision of aileron
movement.

10. Once again re-check horn alignment. When satisfied, glue

both horns in place with thin CA. Saturate the balsa core with thin CA and then harden it
with CA Kicker. This step is very critical as it dictates the bonding strength of the
entire setup. If your slots are too loose, use gap-filling medium CA to fill the voids.

11. When all is done, remove ball link.

12. Repeat 3~11 for the second wing / aileron pair.

Aileron Servo & Push Rod Installation

Aileron servo slot has been precut to accept standard-

size servo. Illustration on the right demonstrates our
intended configuration for left aileron. Refer to illustration
often as we proceed. Let’s work on the LEFT wing first.
Then repeat for the RIGHT wing.

Servo Type: metal gear, 100 oz. in. output torque

minimal, digital servo preferable
Servo Arm: aluminum half arm, 1” length

10. Drop in aileron servo and orient it so that the servo

output shaft is closer to the aileron hinge line.

11. Route servo pigtail out through wing root. Use a

music wire or coast hanger wire to facilitate routing.
Be careful not to damage any of the balsa ribs.

12. Construct push rod. We recommend the following

components which are included in our optional
hardware package;

„ Titanium Turnbuckle Push Rod x1 Hanger 9 #3550

„ 1/4 HD Ball Link x2 DuBro #899

13. Install servo arm. Orient servo arm at 90 degrees to servo case. Hook up servo to
receiver and turn on transmitter while performing this setup for reason mentioned
previously. Turn off radio when done.

14. Hook up push rod to servo arm and EFP control horns. Adjust the turnbuckle push rod
until aileron is in neutral and servo arm is at 90 degrees to the servo body.
Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 21
 COMPONENT PLACEMENT FOR BEST CG:

The recommended Center of Gravity (CG) range is 128 mm (25% CG) to 149 mm(30% CG)
or 5.04’‘ to 5.87’‘ behind the wing leading edge where it meets the fuselage, measured along
the fuselage sidewall. This is a starting point. Adjust CG to match your flying style.

NOTE: 128 mm (25% CG) point is the center of wing tube

Simply support and balance the plane by the wing tube with wing installed.

Our component placement guide is based on the following assumptions;

„ Various components as mentioned in previous sections plus

„ Engine: DA50-R with stock muffler
„ Spinner: AirWild 4” Extra-style spinner with lightened back plate
„ Propeller: AirWild NX 22x8 2-blade propeller
„ Ignition Battery: 6V/1650mA NiMH battery pack
„ Receiver Battery: 6V/1650mA NiMH battery pack

Feel free to make necessary changes to reflect differences in your component selections.

MOUNTING RECEIVER & IGNITION KILL SWITCH

Cross member E8 is specifically for mounting receiver, optical kill switch or even receiver
battery if necessary. There is a gap between E8 and wing tube socket. This will allow you to
route Velcro strips through and secure major components to E8 with it.

Cross member E8 for placement of RX & Optical Kill Switch secured in RX antenna internally routed through to
RX, Ignition Kill Switch & Battery place with Velcro strips the rear turtle deck

PLACEMENT OF RX BATTERY & SWITCH

Location of receiver battery switch has been predetermined for you as shown. Install a high
quality mechanical On/Off switch, i.e. DSC Super Switch, and route wires neatly through
formers.

Use receiver battery as the final counter weight for balancing the airplane. The most ideal
location for our reference setup is “piggybacking” on top of the fuel tank. If your components
are “heavier” than our reference selection, move the receiver battery around to find the best
balance point for your setup.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 22
Default switch location sized to fit Remove Ultracote to mount DSC An example of RX battery
DSC Super Switch. Super Switch. placement – piggyback.

BASIC GUIDELINE FOR ELECTRONICS HOOK-UP

By now all electronic components have been properly placed. It is time to hook up everything
and make things work! The following block diagram illustrate the basic inter-working of all
major components

Connect all components accordingly. Keep your wire routing organized and short. Make sure
your batteries are charged. Next we have to program your transmitter to make everything
working harmoniously.

RECEIVER CHANNEL MIXING SETUP:

We highly recommend using PCM radio for airplane employing electronic ignition as it can
better coupe with electro-magnetic interference generated by this type ignition. Furthermore
we shall also assume that common PCM radio transmitters come standard with necessary
channel mixing functions needed for the following channel setup.

Once again this setup is merely a recommendation. Feel free to adopt your preferred
configuration.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 23
 Control Surface Receiver Channel Remark
Aileron, Left „ Aileron „ Aileron - master channel
Aileron, Right „ Auxiliary 1 „ AUX 1 - slave channel (follows Master channel)
„ Enable master-slave mixing function
„ Make sure trim function of both channels is
controlled ONLY by Aileron Trim (master), and
that AUX 1 trim will not affect anything

Elevator, Left „ Elevator „ Elevator - master channel

Elevator, Right „ Auxiliary 2 „ AUX 2 - slave channel (follows Master channel)
„ Enable Master-Slave mixing function
„ Make sure Trim function of both channels is
controlled ONLY by Elevator Trim (master) , and
that AUX 1 trim will not affect anything

Throttle „ Throttle „ Direct connection

Rudder „ Rudder „ Direct connection

Ignition Kill „ Gear „ Choose any free channel that is controlled by a

2-position switch, i.e. gear
„ Choose a position of the switch that you prefer
as the OFF state and use Channel Reverse
function of your computer radio to set ignition
On/Off state to OFF (status LED is OFF)
„ Then toggle switch to the opposite position and it
should set ignition kill switch to ON state (status
LED is ON)

Once programmed, check movement of ALL control surface for;

„ Correct direction of travel including state of ignition ON/OFF
„ Synchronized movement on both Master & Slave channels
„ Master channel’s Trim controls BOTH Master & Slave channels
„ Slave channel’s Trim DOES NOT affect either Master nor Slave channel
„ Dual rate function controls BOTH Master & Slave channels

CONTROL SURFACE THROWS:

A good starting point for control surface throws;

Aileron: 15 Up / Down

Elevator: 12 Up / Down
Rudder: 45 Left / Right

Once again please consider the above information as only a starting point of your control
adjustment. After you have a feel for the behavior of the aircraft, you can then fine-tune the
throw to match your exact flying style.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 24
 AIRPLANE SETUP AND BALANCING

Balance the airplane in a manner that complements your flying style. Do not forget to balance
the airplane laterally. Move your receiver and battery pack around to balance the airplane for
the best overall performance. Remember, a lighter airplane always flies better. Use your flight
pack and servos to achieve the proper CG. Avoid adding lead weight if possible.

Center of Gravity: Set CG according to instructions first. Once you have had a few flights,
this can be slightly modified to match your flying style.

Lateral Balance: Add weight to wing tips as required so the plane will balance on the
lateral center of the fuselage.

Incidence: Set incidence angles according to plan.

Wing Incidence: 0
Stabilizer Incidence: 0
Engine Thrust: 0 DOWN & 2~3 RIGHT (propeller dependent)

Control Alignment: Adjust the elevators halves and ailerons so they have the same neutral
point, travel end points and transition speed. Pay particular attention to
left & right elevators as any mismatch will result in unpredictable
behavior.

Servo Horns & Adjust all servo horns and arms so they are perpendicular to the linkage
Arms: with the control in neutral. Check for free, unbinding movement.

AIRPLANE FLIGHT TRIM CHART

Control Neutrals: Adjust trims of each control surface for straight and level flight. Then
readjust all linkages so to return transmitter trims back to neutral.
Center of Gravity: Roll airplane into inverted flight. If airplane requires a lots of down
elevator to hold level flight, airplane is nose heavy. If up elevator is
required instead, then airplane is tail heavy.
Up vs. Down Thrust: Fly airplane straight and level, then cut throttle. If airplane abruptly dives,
then increase down thrust. If airplane abruptly climbs, then reduce down
thrust.
Right Thrust: Fly model away from you and then pull up to vertical. If model veers left,
then increase engine right thrust. If model veers right, then decrease
right thrust.
Angle of Incidence: Go into a power-off vertical dive from high altitude. If model pulls to
canopy, increase wing or stab incidence. If airplane pulls to belly, then
reduce wing or stab incidence.

Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 25
Notes:

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Notes:

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Doc. No.# AW70-104-01, Copy Right 2004, AirWild Hobbies, Inc. page 27
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