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Hostetler Extra 300XS 27%, 33% or 40%

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Old 05-21-2005, 10:02 AM
  #1  
Gaiotto
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Default Hostetler Extra 300XS 27%, 33% or 40%


Hi friends,

Did anyone built the Extra series of Hostetler plans in any size that he offered that could talk about its experience? I was plan to built a 27% or 33% version, what do you think about this planes? Could someone put photos of building progress?

Thanks
Érico
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Old 11-21-2005, 10:09 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Erico:

I decided to take the plunge and make this my build this winter. I'm went with the 27% version and plan to run either a DA-50 or Saito 220 in it. I have a H-9 27% extra right now with the S-220 in it. If all goes well with the build, I'm moving up to the 33% Edge. They're supposed to be very nice planes, it takes longer to build them than other plans, and they're a little heavy. Nothing a little lightening holes and open frame work cant handle though.

MPB
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Old 12-14-2005, 10:17 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

I received the plans and most of this plane is balsa. The only ply in it is the firewall, landing gear plates, and a couple of reinforcement pieces. It should come out very light. I'm not going to the trouble of lightening it up, as it should be light as it is. Wendell claims it'll come out at 12.5 lbs with voltage. I'm running gas, maybe a S-220 or S-180 depending on it's rolling weight.

If anyone's interested, I can post pictures of the build. I have the fuse skeleton built and am working on the build up to skin the front half.

MPB
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Old 12-14-2005, 07:37 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Shag555,

I have this plans too and I´d like to see the pictures of the building process, because I´m very interested in building this plane. Could you please post this pictures?

Thanks,
Gaiotto
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Old 12-16-2005, 07:22 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Here's the start of a beautiful project... I was a little sceptical of the framework as it's a very simple build-up from 1/4" balsa. Most of the build-up is 1/8" balsa formers and sheeting afterward. The pics show the start of the fuse. It's coming along nicely and is very strong. Originally, I planned to redesign the formers out of 3/32" ply, and stuck them in AutoCAD. I figured I'd build Wendell's design, then one with the mods, but this thing is really strong with the gussets, etc. Stay tuned, I'll have the turtle deck and hatch work sheeting done shortly.

MPB
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Old 12-16-2005, 07:26 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Here's another
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Old 12-17-2005, 08:11 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Wow!! Beautiful, Shagg...Did you buy the laser cut kit or you are scrach-building this beautiful machine?

Thanks
Gaiotto
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Old 12-17-2005, 08:19 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

I called about the laser cut kit... After getting the plans and seeing how much they wanted for it ($295 US) and it didn't include the cowl, wheel pants or canopy, I decided I'd cut it myself. It turns out that it's working better that way anyway (so far). Seriously, with all the balsa in this framework, I really don't see the need for the laser cut kit. Wendell might have intendeded it that way.

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Old 12-29-2005, 07:43 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Here's an update... Fuse formers are all in place, with exception under the wing, that will come later. 1/32" ply is installed up front, I'm planning on putting a couple of holes in it for lightening purposes. Under the bricks is the spar for the horizontal stab. It's made of sandwitched 1/8" balsa and 1/32" ply. I epoxied and it's setting up tonight.

My helper is working hard as usual!
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Old 12-29-2005, 07:51 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

One question I have for you guys is, where the horizontal stabilizer mates the fuse, plans show 1/4" balsa squared up and into (I think) the 1/4" framework of the fuse. In other words, the rear former appears to be cut, as does the diagonal bracing (as in the attached picture (I pinned it in place over the framework for illustration). Wendell doesn't show any dashed linework for the former or brace that would indicate this is atop the framework and the overhead view of the fuse shows it being boxed into the framework. I guess I'm answering my own question here, but does this look right??? And, will this be strong enough for a 27% airplane??? Obviously, there's more "meat" to be added when the vertical stabilizer goes in and is framed up.

Thanks!

MPB
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Old 12-30-2005, 04:32 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Well I got my answer from Wendell himself. The mount is boxed in, the F8 former gets cut, as does the diagonal brace. The stab is not sheeted, only through the fuse. I'll have to see how this turns out though, as I still think it'll look better fully sheeted (smooth vs stab ribs sticking up in covering). 1/16" sheeting wouldn't add much weight and I could even it up a little by lightening the ribs in the stab.

For those interested, I asked about the Edge 540 plans. Turns out it's a two piece - TUBE mount wing. That'll be my next build!

MPB
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Old 12-30-2005, 05:02 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%


ORIGINAL: shag555


For those interested, I asked about the Edge 540 plans. Turns out it's a two piece - TUBE mount wing. That'll be my next build!

MPB
So, this Extra is a one-piece wing?
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Old 12-30-2005, 10:41 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Yeah, the Extra is a one piece. Wished it was a 2 piece and planned on redesigning it for a 2 piece/tube, but think I'll go with what the plan calls for at least for this one.

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Old 12-31-2005, 09:24 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%


ORIGINAL: shag555

Yeah, the Extra is a one piece.
Nuts. Looks like I'm going to have to go with one of the "new design" laser cut kits; unless I can get off this Extra fixation.

What's the size of the Edge with the two-piece wing?
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Old 12-31-2005, 11:12 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

http://www.aero-sports.com/whplans/edge.html


Steve: The Edge is at 34%, 103 inch wingspan. I'm a nut for Extra's too. Just like the way they look. The link above will get you to the site for the Edge. I don't know if Wendell has the plans modified for the 33% or 40% into a two piece wing? You'd think so, and I never thought to ask before! Would probably be worth checking in to, as at that scale, it's near impossible to carry around a wing that's over 100inches. A guy could scale the 33% down to 27%.

I'll email Wendell next week and check it out!

MPB
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Old 12-31-2005, 07:39 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Well I finished up the horizontal stab, and mounted the 1/4 inch balsa block to mount it into the tail. In installing the ribs to the trailing edge, I squared them up laterally and vertically, but forgot to square them in the 3rd dimension (horizontally). I ended up with four ribs that were out of alignment. I marked actual center of each rib, then squared up a string across the stab where the leading edge would be glued up. The ones out of square were scored against the trailing edge and snapped laterally (but not completely broken off), then aligned correctly and reglued.

I changed my mind AGAIN... Originally I planned on sheeting the stab, but I laid out a scratch piece of covering over it, and it's flat enough that it shouldn't show any concave areas in the covering (I hope).

The trailing edge of the horizontal stab in this design is flat. The elevator leading edges have a very shallow angle to them, and I haven't seen what kind of throws this will have yet (will build elevators tomorrow). I was thinking I could put some trailing edge stock over the ply/balsa/ply trailing edge to attain more throw, I'll see what the build produces first.

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Old 12-31-2005, 07:44 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

The pic above is a "before" shot. Here's one after completion and straightening and shaping of the leading edge.

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Old 01-02-2006, 09:32 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Ok guys... I got the Elevator halves completed today! I started by tracing the trailing edge of the stabalizer to some 1/4 inch balsa and cut it out in one piece. Got all the ribs cut out and laid them up and glued in. This time I made sure that they were straight in all three dimensions (learned my lesson with the stab)! I also used the stab as a jig, and clamped the 1/4 inch leading edge to the trailing edge of the stab. The most time consuming part of building these elevators was all the sanding of leading and trailing edges to get it right! Also, these elevators have a counter balance. The plans called for the stab to be flat where it meets the counter balance, but I added a concave shape to it to clean it up a little. It'll make for a little more difficult covering job, but will look better in the long run.

After sanding out the leading edge, there isn't a heck of alot of throw to these elevators! I'm going with robart hinge pins and haven't blocked the stab and elevator yet, nor have I drilled it to get the final verdict on the amount of throw. That'll come this week. I'm going to purchase one of those jigs for drilling square and on center for compound angles first. I thought about this, and it would have made more sense to install the hinge blocks on the leading and trailing edges of both pieces prior to even gluing anything to them, then drill them and build around them.

Back to the throw... The trailing edge of the stab is flat, so I figure that if there isn't enough throw on the elevators, I can always add some trailing edge stock to it. If that's the case, I'll have to modify the counter balances to get them to mate properly with the stab.

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Old 01-02-2006, 09:42 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Here's another pic. I'll have to get a picture in comparing this build to the H-9 Extra 260, but so far, these planes are very much the same in form (and that's about it!). Looking at the stab and elevator, the H-9 has a wider elevator (leading edge to trailing edge - is this chord???), but Hostetler's design has the counter balances, plus it's about 2 inches wider, so the surface area is about the same - Wendell's might be slightly more. Could this be why there isn't much throw to the elevators (although rudder throw has the same angles).

Anyway, I'll be building the rudder this week, then it's off to the wing!!! I'm going to order the cowl, canopy, and wheel pants this week too.

MPB
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Old 01-02-2006, 09:50 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Just one more shot fitted to the fuse... If anyone wants a scratch build, or a kit (kit cutter) that's comparable to the H-9 260, this is it. It would be nice to have the 2 piece wing, but what the H, you can't have everything. I'm thinking this'll come out lighter than my 260 did.
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Old 01-03-2006, 02:42 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Steve (or anyone else for that matter) - Looks like the 33% Extra 300 from Wendell IS a TUBE wing... Good news for you... Crap news for me... I should have asked in the first place. I really wanted a 27% with tube wing. Wendell advertises that he can plot plans to any scale so the 33% can be reduced to the 27%. I'm into this one pretty deep to bail out now. I'll just finish as-is... 80" isn't that big to worry about lugging it around. Hell, I fit a 72 inch wing in my Geo Metro just fine and that's sitting it from the back of the seat to the hatch! I'll just lay the seat down or better yet, the wife can do without the suburban for 3 hrs over the weekend!

I should have the rudder built tonight, and will start cutting on the vertical stab also. Epoxy cured overnight for the trailing edge sandwitch.

I ordered the fiberglass pieces and cowl from Fiberglass Specialties today.

MPB
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Old 01-03-2006, 04:23 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Nice thread, Shag, thanks for posting. What tools did you use to cut your parts? Scroll saw, band saw, no saw? Have you got a disc sander or sand by hand? Just wondering how much work cutting all the parts is versus a kit cutter.
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Old 01-03-2006, 04:31 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

SitFly - My christmas present was this set of plans and a new dremel scroll saw. It has a 4" disc sander built into the side of it and it is also speed controlled (along with the scroll saw). I'm cutting the big parts out with the scroll saw, the ribs, etc are getting scanned from the original plans, then printed and sacraficed over balsa, etc. I square up as necessary.

Thanks for the compliment!

MPB
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Old 01-06-2006, 07:58 AM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Well Fellas, I got the fin and rudder almost finished last night. Have to sand out the leading edge where the rudder abuts the trailing edge of the fin, and it's all done. Hard to believe it took me all week to complete, but I can only manage about 45 minutes - 1 hour per day through the week. I'll post some pictures of the completed assembly tonight.

The really cool part about all of this, is I'll get to work on the wing this weekend! That in mind, I should get all of the ribs cut out and potentially be able to start building Sunday!

I haven't received any pieces from Fiberglass Specialties yet. They didn't know if they had any pieces in stock or not, and if they didn't, they wouldn't build any till this coming Tuesday. I suppose I'll give them a ring and find out if they shipped or not. I'm not going to do any sheeting till I get these pieces.

Again, on the tail area, I've compared the rudder with the H-9, and it definately has more area than the H-9 Extra 260. Does anyone know if the real deal Extra 300 has more S.A. than the 260, or is this do you guys think this is between Hostetler's and M. McConville's design? I'll get a picture for sure tonight and post it (between differences) if anyone's interested.

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Old 01-06-2006, 09:02 PM
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Default RE: Hostetler Extra 300XS 27%, 33% or 40%

Well as promised, here's the pictures of the rudder and vertical stab. Turned out pretty nice, and is very strong with sheeting only at the root of the stabilizer. I hung the plane from my digital Rapala scale, and so far I'm at 15 oz. I've included a couple of comparison shots of H9's Extra 260. WH's Extra 300 definately has more surface area on both Elevator & Rudder.

I'll be working up the wing ribs tomorrow!

MPB
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