Electronic Equipments

Standard Equipments High Quality Equipments

Motor 2204-14T motor or equal

AXi 2203/52 / AXi 2203/46 / AXi 2203/RACE AXi 2204/54

ESC 8 – 10A ESC

Castle Creations Phoenix 10A / Castle Creations Thunderbird 9 / Hacker Master Eco 08

Aileron Servo

If using 1 servo : 9 grams micro servo If using 2 servos independently : 4 - 5 grams micro servo

If using 1 servo : Hitec HS-65HB / Hitec HS-55 / Hitec HS-5055 If using 2 servos independently : JR DS290G / JR DS188 / JR DS319HV / Hitec HS-35HD / Hitec HS-5035

Elevator and Rudder Servo

4 - 5 grams micro servo

JR DS290G / JR DS188 / JR DS319HV / Hitec HS-35HD / Hitec HS-5035HD

Battery LiPo 2 cells 300-400 mAh (for indoor flight) LiPo 3 cells 300-350 mAh (for powerful outdoor flight)

Receiver 4-6 channels micro receiver (as light as possible!)

Radio

I highly recommend you to use digital computerized radio. It will be very helpful to make setting configurations such as sub trim, travel adjust, dual rate, exponential, throttle curve, and another mixing for this plane.

Required Tools and Adhesives

These are some tools and adhesives you will be needed to finish your Extra XP : 1. Foam-Safe CA glue (highly recommended) or another thin foam glue 2. 3M Blenderm Medical Tape or Fiberglass – Tape or another sticky - strong tape for control surface attachment 3. Sharp hobby knife or sharp cutter 4. A piece of sandpaper 5. 1 mm or 1.5 mm drill bit 6. Scissors 7. Screwdriver 8. Solder 9. Kevlar thread

Foamy Creation Fiberglass Linkage Set

Main Wing Preparation

1. Cut the aileron from the wing section. Using foam-safe CA (highly

recommended), glue two pieces of thin 0.5 mm carbon strip to the Leading Edge

of the wing. First piece for right wing, and second piece for left wing. Make sure

the right-wing carbon strip and left-wing carbon strip is glued together at the

center of the Leading Edge. Cut the remaining carbon strip. Always make sure

that the wing is straight before you glued it.

*Tips : If you want to build lighter wing section, you can “shave” the carbon strip

that will be used for Trailing Edge. This method will save some weight and you

will have some useful thin carbon for Trailing Edge reinforcement, horizontal

fuselage reinforcement, etc.

CAUTION!

When working with the carbon parts, please use safety

equipments like mask, gloves, and safety goggle.

2. Now you can glue the “remaining” thin 0.5 mm (or thinner) carbon strip to the

Trailing Edge of the wing. This method will make the wing is more stiff and rigid.

3. You can add some “thin” carbon strip to the wing tip for additional

reinforcements.

4. If you have “shaved” the 0.5 mm carbon strip, you can also glue the “remaining”

thin carbon strip to the horizontal fuselage for additional reinforcement. This

method will make your fuselage stronger and make your plane more precise.

Main Wing and Horizontal Fuselage Assembly

5. This is the important step of building the Extra XP. Using flat table, you should

precisely glue the horizontal fuselage to the main wing. Also make sure that the

horizontal fuselage’s and wing’s tab line is straight. Use a ruler to ensure that

those tab lines are precisely straight. Also measure the distance from wing tip

to horizontal stabilizer’s tip. Make sure that both right and left section are equal

in distance.

6. Now you can glue the nose section to the main wing. Again, make sure that the

horizontal fuselage’s, wing’s, and nose’s tab line is straight. Use a ruler to

ensure that the tab line are precisely straight.

Every shockflyer has some weak

points. The junction of the main

wing and horizontal fuselage is such

a weak point. For additional

reinforcements, I recommend you

to glue a small piece of fiberglass

cloth for those weak points.

Aileron Preparation and Attachment

7. Prepare the aileron section. Bevel the bottom-front side of the aileron straightly

using sharp knife. Bevel both right and left aileron carefully. This is important for

maximum deflection of the aileron.

8. Now you can attach the aileron section to the main wing. I highly recommend

you to use 3M Blenderm medical tape as a hinge. It sticks very well to the

Depron’s surface.

9. See the circled positions of the wing in the picture below. Now place some little

pieces 3M Blenderm tape to those “circled” positions of the wing for additional

hinge reinforcement. Use this method for both sides of the wing.

After that, make sure that both ailerons can deflect easily (up and down)

without any friction with the other section.

Elevator Preparation and Attachment

10. Now you can attach the elevator to the horizontal fuselage (tail section) using

3M Blenderm tape or another sticky thin tape. Slightly bevel the front side of the

elevator symmetrically (both upper side and lower side are slightly beveled). I

like to use “8 method” for the hinge. This method is excellent because it will

keep the tension of pull-pull wires from displacing the hingeline and the elevator

will stay in place for long time. Here are the steps of “8 method” :

Take 2 pieces (about 1 x 1.5 cm) and tape the sticky sides (across the 1

cm length) together to form an overlap of approximately 0.5 cm. The result

of this should be : 0,5 cm of “neutral“ tape from both sides and 2 cm of sticky

tape. Take prepared tape and glue one of the sticky sides on the top of

stabilizer. The other sticky side of the tape should be glued on the bottom

of elevator.

Repeat those steps along the elevator hingeline.

11. For additional reinforcement, you can

add “V” shape of thin carbon strip

then glue it to the elevator.

Lower Fuselage Attachment

12. Prepare the lower fuselage. Attach it to the horizontal section of this plane.

Using flat table, make sure the lower part of vertical fuselage is straight and

perfectly perpendicular to the horizontal section. Add some heavy objects to

press the horizontal fuselage dpwn to the table. Now you can glue it carefully.

Do not use too much glue because it will add much weight to the plane.

*Tips : For accurate construction, use a pair of square object like card or

another object that have 90-degree angle. Place these object between

horizontal fuselage and bottom part of vertical fuselage to make them

perpendicular.

Carbon Wing Strut Preparation and Attachment

13. Now we need to prepare main wing support. Mark a small node on the lower

fuselage at the center of main wing chord near to the lower fuselage’s edge.

Glue a small piece of 0.5

mm fiberglass or small

piece of Depron at this

point. This will be an

attachment point for the

wing support carbon rods.

14. Notice a small mark of the wing support attachment points (at the Leading Edge

and Trailing Edge of the wing). Cut 4 pieces of 1 mm carbon rod (each piece is 25

cm long) and sand each tips of the carbon rods. Now you can glue those carbon

rods to the main wing. (See the picture below)

*DO NOT GLUE those 4 carbon rod’s tips at the lower fuselage this time.

15. Before you glue the carbon rod’s tips to the fuselage, make sure that the lower

fuselage is perfectly straight and perpendicular to the wing. Place the plane to a

flat table. Use some weight to press it down to the table. Now double check the

lower fuselage position and glue 4 carbon rods to the fuselage.

16. Now you can glue two Depron SFG’s to the wing support carbon rods.

Carbon Fuselage Strut Attachment

17. Now you can glue 1 mm carbon rods to reinforce fuselage structure. Always

make sure that the lower fuselage is perfectly straight and perpendicular to the

horizontal fuselage. Sand the tips of each carbon rods before gluing to increase

adhesion.

(See the picture below)

If you decide to have more rigid and strong aileron section, you can add an

optional reinforcement. Use thin 0.6 mm or 0.7 mm carbon rods to reinforce

both of the aileron. Before glue the carbon reinforcements, always make sure

that the aileron is straight and flat. Use some heavy object to press it down to

the table.

The last picture shows all carbon reinforcements for fuselage and main wing.

Landing Gear Attachment

18. Before working on the top of the fuselage, it is time to prepare and install the

landing gear. The landing gear legs are made from 1.5 mm carbon rod and are

16,5 cm long. Mount the gear legs as shown in the picture below, angled slightly

forward towards the motor. This will provide stability when standing on the

ground. For additional reinforcement, you can glue a small piece of 0.5 mm

fiberglass or small piece of Depron to the junction of the landing gear legs on the

fuselage.

You can add the wheel pants for more beautiful looking plane.

Aileron Servo Preparation and Attachment

19. Now prepare the aileron servo. Use the recommended servo for better

performance. If using two servos, you can place the servo at the SFG of each

wing side. If using one servo, you can use the provided anti-differential servo

horn. Always sand the 0.5 mm fiberglass

parts before glue it to the other parts to

increase adhesion.

Those pictures show the attachment steps

of aileron servo (using one servo).

Glue the aileron horns at the marked place of both ailerons. Make sure that the

linkage point is aligned to the hingeline. Aileron pushrods are made from 1 mm

carbon rod. Use the provided shrink tube to connect the pushrod to the aileron

horn and servo horn. Before you attach the pushrods, make sure that the

aileron servo horn is centered and both ailerons are in the neutral position.

Measure the distance beetween servo horn and aileron horn. Both Left and

Right pushrods should have the same length. Add glue to the shrink tube at

the pushrod and horn to keep it in the correct position and avoid shrink tube

flexing.

Upper Fuselage Attachment

20. After you have done, now is the time to attach the upper vertical fuselage. Make

sure the upper fuselage is perfectly straight and perpendicular to horizontal

fuselage.

Pull-Pull Linkage for Rudder and Elevator Set-up

21. Rudder is attached to the fuselage using same method of elevator attachment

(using “8” hinge method).

22. After you have installed the rudder, now is the time to set-up pull-pull linkage.

Install the pull-pull horn to the rudder (see the picture below). Make sure that

the horn is perpendicular and the linkage hole is aligned to the hingeline.

23. Prepare the rudder servo and the pull-pull horn. Sand the surface of the

fiberglass pull-pull horn and glue it to the provided servo horn. Glue a little piece

of shrink tube for additional reinforcement.

24. Install the rudder servo to the provided position at the fuselage. I like to glue a

little rectangle Depron piece to make additional reinforcement for the rudder

servo.

25. Now prepare the provided fishing line. Cut the fishing line about 120 cm long.

First, make a couple loops of fishing line at the Right side of pull-pull rudder

horn. Glue the loops to lock it.

26. Before tightening the pull-pull line, now is the time to reinforce the vertical

stabilizer. Use remaining 1 mm carbon rod to reinforce the vertical tail. This

method will make your tail more rigid and doesn’t flex when the pull-pull

tension is applied. Make sure that the carbon rod doesn’t frict with the pull-pull

line. (See the pictures below)

27. Then, move to the pull-pull servo horn. Insert the fishing line through the Right

servo horn hole then insert it through the Left servo horn hole.

*DO NOT GLUE the pull-pull fishing line at the servo horn this time.

28. After that, move to the Left side of rudder pull-pull horn. Before lock the pull-

pull line, you should adjust the tension of the fishing line and make sure that

the tension is balance so the rudder is solid and doesn’t flex at neutral

position. Use the provided Copper Sleeve to lock the pull-pull fishing line.

29. Using the Sub-Trim function on your radio, now you can adjust the center

position of the servo horn.

30. By pulling or pushing the Right or Left pull-pull line, adjust the rudder to its

neutral position.

31. After you have done, glue the fishing line at the servo horn to lock it.

Those steps (number 25, 27, 28, 29, 30, 31) are also used for elevator

pull-pull set-up.

Motor Preparation and Installation

32. Prepare the fiberglass motor mount. Fit your motor mount screw hole to the

fiberglass motor mount using 1 mm or 1,5 mm drill bit. Sand the fiberglass

motor mount to increase adhesion when glued. After you’re sure that the motor

fits nicely to the fiberglass motor mount, you can glue the fiberglass motor

mount to the fuselage.

33. Connect your motor wires to the ESC outputs. I like to solder the motor wires

directly to the ESC. You can save some weight by removing default ESC wires.

Make sure that the motor is running in the correct direction (counter clockwise).

34. Screw the motor to the fiberglass motor mount. The motor should be mounted

with NO UP / DOWN THRUST and 1 - 2 degrees of Right thrust. Use a little

spacer (you can use small piece of

plywood or balsa wood) to make the

1 - 2 degrees of Right thrust.

Battery Installation and Center of Gravity (CG) Adjusment

35. Now is the important step of adjusting your plane. Your plane’s flying

characteristics are depend on your CG location. Install the suggested propeller

to the motor. Now you can place your battery near to the aileron servo. Adjust

the CG of your plane by moving the battery forward or backward. If you like to

fly precision aerobatic, the CG location is about 21,5 cm from motor mount. If

you like to fly slow 3D aerobatic, move the CG slightly backwards.

36. When the battery position is fixed, you can built a small Depron box to hold the

battery in place. The battery also held in place using small pieces of Velcro tape

and 3M Blenderm tape.

37. Here’s a picture of my battery placement. My CG is about 21,5 cm from motor

mount. I usually use 2s 350 – 370 mAh battery (22-25 grams).

Radio Setup and Control Deflection Adjusment Every pilot has his own preferences for radio set up. So, please set this plane as comfortable as your feel. This is my personal setting, just for some references: Aileron Up : 60 degrees Down : 55 degrees Elevator Up : 65 degrees Down : 60 degrees Rudder Rudder should be traveled from Left to Right inside the elevator cut out. I am using JR Radio Control. Kindly note that in Futaba or Hitec radios, the value “+” of Exponential should be “-“ . Aileron : +55 % of Exponential Elevator : +35 % of Exponential Rudder : +25 % of Exponential Once again, thank you very much for purchasing this product. We wish you have many hours of fun and safe flying. Please fly this plane only in areas where it can be operated safely, and can

not cause harm to people.

If you have any questions, please contact us by email : annaskaruniawan@gmail.com

www.facebook.com/FoamyCreationAeroDesign

Created by : Sri Annas Karuniawan

Last revised January 4th, 2014