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Extra 260 Assembly Manual Specifications Wing Span: 40 inches Wing Area: 350 in Fuselage Length: 35.5 inches Weight (ready to fly): 19 to 23 oz. Wing Loading: 7.8 to 9.5 oz/ft Designed by Jim Vigani Version 1.0 – 11/9/07...
Introduction: Thank you for choosing the Extra 260 airplane. We have taken great care to provide a design and kit components that, when properly assembled, will give you a high quality model with outstanding performance. While the assembly is not complicated, the quality and ultimate performance of your model will depend on the care you take while building.
Kit Contents: Before you start the assembly of this model, check to make sure that there are no missing parts and that none of the parts have been damaged during shipment. If you have any questions with the assembly or flying of this model, please contact us and we will be happy to assist you. If you need replacement parts please provide the model name.
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Figure: General Comments on Assembly: While not difficult to assemble, the Extra 260 kit is intended for persons with some building experience. As such, the instructions are presented as a simple sequence that, when followed, will help ensure that the airframe turns out straight and light.
Depron foam. Graphics: The Extra 260 comes with printed vinyl graphics. Extra care in cutting out and applying the vinyl panels will result in a painted look for your plane. Some people prefer to lightly mist the surface with “Frebreze” before applying the vinyl. This allows the vinyl to be repositioned while applying them.
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Step 1 Glue the wing root doubler in place with foam safe CA being careful to ensure the wing openings perfect alignment. Tip: Before joining, apply CA to doubler lightly spray kicker on the fuse skin. Step 2 Using the plywood nose doubler as a guide, glue the top front doubler in place with foam safe CA.
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Step 3 Glue the lower rear doubler in place with foam safe CA. NOTE: The lower rear doubler needs to be positioned 3 mm from the edge of the skin. An alignment tab is provided at the rear of the part to ensure proper alignment.
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Step 6 Trim front doubler alignment tab flush with upper rear doubler. Repeat Steps 1 to 3 for the other skin assembly making sure to make a LEFT and a RIGHT side version! Step 7 assemble plywood crutch pieces and check for fit.
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Step 8 Glue the plywood crutch parts landing gear mount parts together with medium CA. Insert foam formers and glue in place with medium foam safe CA. TIP: tack glue the plywood pieces in place with thin CA then re-glue with medium Landing Gear Mount Assembly Glue the plywood landing...
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Glue the landing gear wire torsion support in place with medium CA making sure the slot in the support aligns with the hole in the landing gear mount. TIP: Insert a piece of 3/32 wire into the hole and use as an alignment guide.
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Step 10 Test fit the skins on the crutch and check that the slot in the rear of the skin mates with the alignment tab on the rear of the crutch. Step 11 Glue the crutch to one skin assembly from the nose to just behind the wing opening with medium foam safe CA.
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Step 15 Glue the top cowl skin in place with medium foam safe CA. Tip: Before gluing, lightly score the backside of the top skin with an old ballpoint pen to allow the foam to be bent around the nose without cracking. Pre- bend the foam before gluing in place.
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Step 18 Glue the bottom cowl skin in place with medium foam safe CA. Tip: Before gluing, lightly score the backside of the bottom skin with an old ballpoint pen to allow the foam to be bent around the nose without cracking. Pre- bend the foam before gluing in place.
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Step 20 Cut a 3” piece off the front of the fuselage lower skin. Save the piece. This front piece will be glued in place after the rudder pull-pull system has been installed. Step 21 Glue the lower fuselage skin position with medium foam safe CA.
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Step 26 Place a mark 2 ” behind the leading edge at each wing tip. Place another mark 3 ” behind leading edge each wing root. Step 27 Glue the 3 mm foam wing alignment tabs in place on the left wing using foam safe CA staying sufficiently away from the spar location mark to...
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Step 28 Mark the center of the spar and test fit it in the wings. Glue the spar into place with Gorilla Glue or 15-minute epoxy. Align the spar with the spar location marks on the wing panels. Step 29 Repeat for the other wing making sure to align the root...
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Step 30 Push the wing center joint together making sure the wing root airfoil profile both wings match at the center. Step 31 Carefully sand the wing tip profile and spar end to remove any irregularities. Glue the wing tip caps onto the wing using foam safe CA and foam safe kicker.
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Step 34 Test fit the wing in the fuselage. FORCE! If the fit is tight, sand fuselage opening to fit. Make sure the wing is centered on, square fuselage. With the wing properly aligned, tack glue it in place with medium foam safe CA.
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Step 36 Using the end of the 3/16” diameter carbon elevator joiner, gently create shallow grove elevator joiner cutout. Step 37 Secure the 3/16” diameter carbon elevator joiner in place with epoxy. Tip: For a lighter joint, a mixture of minute epoxy micro balloons can be...
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Step 40 Using sanding block, bevel the leading edge of the elevator as shown allow movement elevator when hinged. Step 41 Temporarily secure elevator stabilizer with tape. Mark the position of elevator hinges with strips of ” wide painter’s tape. Use 3 hinges on each side of the elevator.
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Step 42 Cut the tape along the hinge line and remove the elevator. Step 43 Using your Exacto knife, carefully cut a slit along centerline of both the stabilizer and elevator at each hinge location. Test fit the hinges into the slits.
Step 44 Test fit the stabilizer in fuselage check that fits square to the fuselage and wing. Remove the stabilizer insert elevator fuselage slot. Insert stabilizer position, making sure it is square to the fuselage and the wing. Glue the stabilizer in place with medium...
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Step 46 Using the sanding block, bevel the leading edge of the ailerons as shown to allow for movement of the ailerons when hinged. Step 47 Temporarily secure the ailerons to the wing with tape. Mark the position of the aileron hinges with strips ”...
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Step 48 Cut the tape along the hinge line and remove the ailerons. Using your Exacto knife, carefully slit along centerline of both the aileron wing trailing edge each hinge location and glue the hinges in place NOTE: that the wing has a glue seam along the centerline of the trailing edge.
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Step 50 Test fit the servos in the holes. Mark the location plastic servo mounts and remove the servos. Glue the servo mounts in place with foam safe CA. Drill a 1/32 inch diameter pilot hole in the servo mounts each servo mounting lug location.
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Step 51 Sand the edges of the 1/32” plywood control horn parts to remove the edge caused by the laser cutting. Slide all the pieces together and then run some thin CA along the horn edges and in the joint between the horn and support.
Landing Gear Installation: Step 54 Solder a #2 washer on the landing gear. as an inner wheel retainer Tip: Drill a 3/32” hole in a scrap block of wood to use as an alignment tool. Lightly sand the axel washer ensure good bonding of the solder.
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Step 57 Secure the landing gear mount cover in place with screws provided. Step 58 Tie the wire tailskid to the plywood mount with unwaxed dental floss or thin wire. Secure with CA. Attach the plywood tailskid mount to the rear fuselage using foam safe CA or...
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Step 59 Secure the wing servos in place with the servo mounting screws provided with servos. Do not over- tighten the screws as you may strip the screw holes. Step 60 Route the aileron servo leads through the interior of the wing, and out through the exit hole.
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Elevator Servo Installation: Step 62 Securely glue elevator servo mounts in place with medium foam safe CA. Step 63 Install elevator servo servo mounts outside fuselage. Pre-drill the screw holes with 1/32” drill before installing the screws. Do not over-tighten the screws as strip the screw holes.
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Step 66 Secure the rudder pull-pull cord on the rudder servo control horn using provided metal sleeves. TIP: Slip the control line through the tubing, then through the control horn, and back through the tube. Squeeze tube with some pliers to flatten it, and then add a drop of thin CA at the end of the tube away from the control horn.
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Step 69 Install the 3” section of the fuse bottom that trimmed off in Step 20. TIP: An access hole can be cut for access to the servo horn if desired. Step 70 Mount the motor using #2 wood screws and washers.
Step 73b Velcro strip battery. Pre-flight checklist Balancing: We recommend that you perform initial flights with the CG 3¾ to 4 inches behind the leading edge at the wing root. Adjust the CG to get the flight characteristics that suit your taste. Electrical Components: Check that all electrical components are securely attached and the all plugs are fully seated.