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  1. #201
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The first pictureis the choke in the open position. To close the choke you push on the nylon ball link.
    The second pictureis the choke in the closed position and the aluminum arm is now pointing down. To open the choke you pull the arm forward and up.
    The choke is easy to operate and nothing ishanging out of the cowl.
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  2. #202
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    I bolted the engine to the firewall using some blue Loctite. The header and canister installs were next.
    The headers had been shortened to allow the coupler to slide all the way onto the header and still leave a 1/8" gap between the header and the canister.
    I installed the coupler on the canister and added the clamp. I drilled a 1/16" hole in the smallest corner of the opening in the clamp.
    I shortened a couple #2 x 9/16" servo mount screws and put them in with some red Loctite.
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  3. #203
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    I put the clamp on the header before sliding the header into the coupler.
    After the canister and header are in their final position the clamp is put on the header side of the coupler. I put the clamp behind the bumps on the header.
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  4. #204
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The hardware for the headers includedeight bolts of one size, four smaller bolts, and four gaskets. I chose to use the eight bolts. I'm not sure what the four smaller bolts are for.
    Tightening the inside bolts on the "2 into 1" headers requires a shortened allen wrench.
    I didn't use the gaskets. I chose to use Permatex high temp silicone for the gasket.
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  5. #205
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The high temp silicone is applied around the exhaust openings.
    A little excess squeezes out and can be cleaned up with a paper towel.
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  6. #206
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The KS Soft Mounts already had three of the four lock nuts tightened. The lower inside lock nut is the only one left to tighten after the canister is put in.
    Since I reversed the headers and mounted the canisters to the outside there is lots of room to operate a ratchet wrench to tighten the lock nut.
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  7. #207
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The canister was mounted so the exhaust would exit between the carbon tape going down the center of the fuselage and plywood plate that supports the rear landing gear former.
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  8. #208
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    DA sells silicone extensions for the canisters. The pair weighs 1.2 ounces.
    DA suggested installing them with a zip tie above the cross hatch that has been milled into the exhaust exit.
    The other canister is installed the same way.
    One huge advantage of the composite airframe is the amount of room available for mounting canisters. There is easy access to everything canister related.
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  9. #209
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    The exhaust extensions are a bit too long.
    They trim very easily with scissors.
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  10. #210
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC

    Great Job Dean,

    Can you tell me how this compares to other Comp-Arf's you have flown?

    Im about to pull the trigger on one but I just want your opinion...

    Currently I am in Nigeria for the next possible 3 to 5 yrs, flying Jets and a 35% SBACH, my team here has more than 15 Airplanes and another 20 in the Mix of things, plus my Ultra Lightning Just arrived.

    Let me know what you think!

    Darcy
    G-Force Composites
    Composite-Arf
    Jet Cat
    King Tech
    JR Radios
    Fromeco Scale Avionics
    NAF AFIT

  11. #211
    Dean Bird's Avatar
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    RE: CARF-Models 2013 Series 3.1m Extra 330SC


    ORIGINAL: mu2driver

    Great Job Dean,

    Can you tell me how this compares to other Comp-Arf's you have flown?

    Im about to pull the trigger on one but I just want your opinion...

    Currently I am in Nigeria for the next possible 3 to 5 yrs, flying Jets and a 35% SBACH, my team here has more than 15 Airplanes and another 20 in the Mix of things, plus my Ultra Lightning Just arrived.

    Let me know what you think!

    Darcy
    Nigeria? Wow!!

    The "2013 Series" has even more of the work done by the factory.

    http://www.carf-models.com/public_ca...uct&proId=2658

    They mount the cowl now. The hatchis installed by the factory. The phenolicarms on the control surfaces are installed by the factory. I'm guessing you could get it RTF in about 3 days.

    Check the flight reviews of others on page 1. Nothing but positive reviews.

    Show us some pics when you get yours!!
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  12. #212
    Dean Bird's Avatar
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    The fuel tank, fuel dot, and fuel line installations were next.

    The fuel tank was secured to the tray with zip ties. I put Velcro on the tank underneath the zip ties. The connections had wire wraps.

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    The single line is feeding two carburetors, so I used a very large I.D. tygon tubing.

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    The wire wraps were sold by my local hobby shop.

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  13. #213
    Dean Bird's Avatar
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    The fuel dot is from Madison Products and is made specifically for the 5/16" I.D. tubing.

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    I didn't want the fuel dot being tightened on the fuselage skin. I made a plywood ring standoff for the housing to rest on. The standoff is glued to the plate that will be glued on the inside of the fuselage.

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    The nylon washer for the housing will rest on that standoff.

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    Last edited by Dean Bird; 08-23-2013 at 10:00 PM.
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  14. #214
    Dean Bird's Avatar
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    The hole in the fuselage side is marked the same size as the standoff. I chose to put it below the white and yellow wedges in the paint scheme. I wanted to keep those looking visually clean.

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    The hole is opened up with a Dremel drum sander to be a perfect fit for the standoff.

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    The complete fuel dot is assembled. Notice how the standoff keeps the nylon washer and fuel dot housing 1/8" above the mounting plate.

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  15. #215
    Dean Bird's Avatar
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    The completed fuel dot is glued in from the inside with Hysol. The area was sanded lightly and cleaned with denatured alcohol before gluing it in.

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    Here is the completed installation without the cap screwed in.

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    Here is how it looks with the cap screwed into the housing.

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    There is no pressure on the fuselage skin. The nylon washer underneath the fuel dot housing is level with the fuselage skin, but it tightens down onto the plywood ring underneath it, not the fuselage side.
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  16. #216
    Dean Bird's Avatar
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    These pictures are inverted.

    The line to the carburetor has a "T" fitting at the fuel dot. This is with the line pulled out for filling.

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    This is with the fuel dot screwed in and ready for flight.

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    The "T" fitting is hung from two zip ties looped through one of these "Kwik Klips" from my local Ace Hardware store.

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  17. #217
    Dean Bird's Avatar
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    I chose to run a single fuel line from the tank out past the firewall. After the fuel tubing goes through the firewall a "T" fitting from PSP was added.

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    The first line on the "T" is added with the length necessary to reach the front carburetor. The second line on the "T" is the same length. I'm told that makes starting easier because fuel reaches both carburetors at the same time when they are choked.

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    Both lines get a wire wrap at the "T" fitting.

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  18. #218
    Dean Bird's Avatar
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    The fuel line for the rear carburetor needs to be secured since it has the extra length that isn't needed to reach the carburetor. I chose to use a 3/8" cable clamp from my local Ace Hardware store.

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    I screwed the cable clamp to a small block of 1/4" plywood that had been thick CAed to the center of the firewall. The fuel line connections to the carburetor got a wire wrap.

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    Here's the front view. LOTS of room to do this work with the headers mounted to move the canisters outward instead of inward.

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  19. #219
    Dean Bird's Avatar
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    I wanted to mention a change that was done after these pictures. On the 3rd flight of the plane I went to full throttle for the first time. The engine would cut out a couple times on the upline. I noticed a lot of air in the line when I was defueling at the end of that first day.

    The only barbs that are designed for this 5/16" tubing are the ones on the Madison Products fuel dot. Air was getting sucked into the line at full throttle. I went back through all the fittings, removed the couple that were small tie wraps and put two wire wraps on each fitting. The problem with air getting into the fuel line went away.
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  20. #220
    Dean Bird's Avatar
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    It's time to finish installing everything on the motor dome.

    I zip tied the two Hall sensor leads together on top of the crankcase.

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    Then I connected the sensor leads to the ignition and put heat shrink tubing on the connector.

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  21. #221
    Dean Bird's Avatar
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    I used Split Wire Loom Tubing (from my local Ace Hardware store) over the spark plug leads anywhere they could contact anything else.

    Click image for larger version. 

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    You can see a wire keep on the motor dome securing the sensor lead and red Velcro straps securing the spark plug lead for the rear cylinder on this side.

    This ignition is for the rear cylinders so the other spark plug lead is routed to the rear cylinder on the other side.

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    The sensor on the top of the engine is for the front cylinders. The ignition on this side is connected to that sensor. One spark plug lead is connected to the front cylinder on this side. The other spark plug lead is routed to the front cylinder on the other side.

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  22. #222
    Dean Bird's Avatar
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    The bottom half of the cowl is bolted on and the baffle installed.

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    The air scoop is installed on top of the baffle.

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    I added a wire keep and Velcro to protect the sensor leads from any abrasion.

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  23. #223
    Dean Bird's Avatar
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    Before the bottom half of the cowl was bolted on I had cut holes for cooling where suggested by the instruction manual.

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    Before mounting the top half of the cowl I added 1/64" plywood shims where the two halves of the spinner ring bolt together.

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    The shims provided a perfect match between the rings on the top and bottom half.

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  24. #224
    Dean Bird's Avatar
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    The cowl is bolted on with twenty M3 x 12 socket head bolts. They seemed way too long to me. I weighed the bolts and they were .6 ounces.

    Click image for larger version. 

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    I wanted to use much shorter bolts and also use a neoprene washer to protect the paint on the cowl. This plane will last forever so I wanted to keep the paint looking good.

    I got a bag of M3 x 8 button heads and washers from McMaster-Carr.

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    Twenty of the button heads with their washers only weighed .4 ounces.

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  25. #225
    Dean Bird's Avatar
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    I'm using a 6" carbon fiber spinner from Azure Hobbies. The spinner bolt that came with it was a little too long and had to be shortened.

    Click image for larger version. 

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    With the prop and spinner mounted, the nose is done!!

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