OVERHAULIN' - FG STYLE: Comp-Arf 2.3m Extra

[phippsj]

I've decided to overhaul my 5 yr old Comp-Arf 2.3m Extra 330L. This is more than a build thread, it's a "rebuild" thread.

I'll be taking you through my steps of stripping down an existing composite plane with over 200 flights on it and upgrading/re-installing/rearranging basically everything. Even new paint!

My goal is to have it complete for Joe Nall 2010.

Stay tuned. More to come!

[classclown]

Awesome! I'm doing the same thing right now to a 2.6m 330S, but am keeping the fantasy scheme.

[CCDave]

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[LawnJockey]

Sweet. I just picked up a 2.6m 330 in the Schulman Scheme I need to redo.

LJ

[BreadBowl]

Are you missing a '0'? 200 flights isn't nearly long enough to have to redo an airplane.

[phippsj]

Here a few pics of the plane before I started tearing it apart. Lots of broken, torn & missing fiberglass. Normal wear and tear.

[phippsj]

Here is a quick list of overhaul items:

• ZDZ-80 to be replaced w/ DA-85. Wrap-around muffler again. No room for a can in this airframe.
• New cowling. Original one is beat-up and the cut-outs will be all different for the DA-85.
• Maybe a new motor dome. I'll have to see how different the DA-85 will be.
• Re-tint the canopy.
• Re-use the spinner if possible.
• New wheel pants.
• Titanium axels
• Update tail wheel
• Repair the tears at the main gear exit slots.
• Repaint the fuse and top of wings back to original white color & add vinyl graphics.
• Send all flight surface servos back to Horizon for rebuild.
• All new wiring to custom lengths.
• Maybe a Smartfly power board.
• Replace existing shelf for receiver, etc with something custom.
• Maybe add smoke system?
• Replace original phenolic control horns with dual carbon plate horns.

[phippsj]

The ZDZ-80 is out and on its way to a new home.

[phippsj]

The throttle & choke servos were mounted on the motor dome to help get weight up in the nose for balance. This is great until you have to replace one of them. I hope the motor dome can be used with the DA-85. A new one is pricey.

[phippsj]

Here's a view of the front of the fuse without the motor dome attached. Easy to get to all those hidden places and check for cracked/broken stuff.

[ExtPlt]

Cool. I have the same plane with the fantasy scheme sitting around waiting to be redone also. It has a 3W 85bi twin that also needs to be sent in for maintenance. I hate the fantasy scheme and want to repaint it. What are you going to use for paint and who are you going to get your new parts from?

[phippsj]

Paint will be PPG from Radio South. Replacement parts will be from Comp-Arf, Andy Kane. Control horns will be custom made. All the other purchased gear will be from Airwild and others.

[MikeC3D]

You can fix the existing parts if you want, it will be WAY cheaper than buying new stuff. I have a 3m 260 that was damaged pretty bad and Bob (sensei)is helping me repair everything. But be super careful or you will add alot of weight back to the plane , especially when you paint it. When this plane was flying it had 11oz of lead in the nose to balance it. Im also going to repaint it so we are going to move the wing tube back about 2" to compensate for the weight of the paint. We are using half oz cloth and medium ca to do most of the repairs, and after it is sanded back down smooth , you can hardly tell there was a repair done. And I wouldnt even attempt to remove the control horns, you will do more damage than good trying to get them out. Good luck...

Mike C

[phippsj]

I have the fuse picked clean. The servos are ready to go back to Horizon for overhaul. Much cheaper than buying new ones.

Next, I will pull the main and tail gear and rudder and start repairing/prepping for paint.

[phippsj]

Got ahold of a lightly used DA85 to replace the ZDZ-80. I'll send it to DA for them to check it out and perform any updates. Can't beat that 3 year warranty!



I need to cut out all the phenolic control horns to make room for the dual carbon plate horns. Slow and easy with a dremel should do the trick.