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Extreme Flight EDGE 540 Assembly Manual
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Extreme Flight EDGE 540 Assembly Manual

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Assembly Manual / Airframe – 106" Edge 540
Thank you for purchasing this 3DHobbyShop by Extreme Flight ARF RC aircraft. If you have
any issues, questions, concerns or problems during assembly, please contact our tech
department at: Info@extremeflightrc.com or 770-887-1794 10am-5pm Eastern Monday thru
Friday.
SAFETY in Assembly
During assembly of this aircraft, you will be asked to use sharp knives and hobby adhesives.
Please follow all safety procedures recommended by the manufacturers of the products you use,
and always follow these important guidelines:
ALWAYS protect your eyes when working with adhesives, knives, or tools, especially power
tools. Safety glasses are the best way to protect your eyes.
ALWAYS protect your body, especially your hands and fingers when using adhesives, knives,
or tools, especially power tools. Do not cut toward exposed skin with hobby knives. Do not
place hobby knives on tables or benches where they can roll off or be knocked off.
ALWAYS have a first-aid kit handy when working with adhesives, knives, or tools, especially
power tools. ALWAYS keep hobby equipment and supplies out of the reach of children.
SAFETY in Flying
This is NOT a toy! It is a very high-performance RC airplane capable of high speeds and
extreme maneuvers. It should only be operated by a competent pilot in a safe area with proper
supervision.
ONLY fly your aircraft in a safe, open area, away from spectators and vehicles and
where it is legal to fly. NEVER fly over an unsafe area, such as a road or street.
NEVER fly near overhead power or utility lines. If your airplane ever becomes stuck in
a line or a tree DO NOT attempt to retrieve it yourself. Contact the authorities for
assistance in retrieving your aircraft. Power lines are DANGEROUS and falls from
ladders and trees CAN KILL!
Never fly too close to yourself or spectators.
Spinning propellers are DANGEROUS!
Never run your motor inside a house or building with the propeller attached Remove the
prop for safety. Always fly within your control.
Always follow manufacturers instructions for your radio system.
Always preform a pre-flight check of your aircraft to be certain of the aircraft's
airworthiness.
Always obtain proper insurance before flying. Always fly model aircraft in accordance
with the Academy of Model Aeronautics (AMA) Safety Code. Visit the AMA's website
at
www.modelaircraft.org
for more information.

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Summary of Contents for Extreme Flight EDGE 540

  • Page 1 Assembly Manual / Airframe – 106” Edge 540 Thank you for purchasing this 3DHobbyShop by Extreme Flight ARF RC aircraft. If you have any issues, questions, concerns or problems during assembly, please contact our tech department at: Info@extremeflightrc.com or 770-887-1794 10am-5pm Eastern Monday thru Friday.

  • Page 2: Limits Of Responsibility

    Extreme Flight provides high-quality aircraft and components to it's customers and end users. These aircraft and components are assembled by the end user to produce a flying model. It is beyond Extreme Flight's control to monitor the end user's completed aircraft. Therefore, Extreme Flight in no way accepts or assumes responsibility or liability for damages resulting from the end user assembled product.

  • Page 3: Let's Get Started

    natural property of balsa wood. As your airplane adjusts to the weather in your part of the world, wrinkles may appear and disappear. Wrinkles may be removed with the gentle application of heat to the covering material on your airplane. The best tools to use are a heat gun and covering iron. Apply the heat gently: the covering material will shrink as you apply the heat, and this will remove the wrinkles.
  • Page 4 Using a soldering iron or hobby knife, remove covering from forward fuselage areas. 1. Front Anti-rotation pin 2. Wing Safety Pin 3. Wingtip( Factory Cut) 4. Cut either one for aileron servo leads. 5. Wing bolt 6. Rear Anti-rotation pin Next remove covering for the horizontal stabilizer bolts and front stab carbon tube.
  • Page 5 Remove tail wheel assembly set screws one at a time and re-torque using blue loctite. Install tail wheel assembly using 3x-4-40 bolts and washers. Use blue loctite on the bolts.
  • Page 6 Contents of landing gear hardware bag. The axles come pre-drilled and the pin is included in the hardware bag. To get the proper spacing you will need 1 collar and one washer on the inside of the axle and then one washer on the outside of the axle as shown.
  • Page 7 Take note of the washer and wheel collar as discussed above. Now attach the assembled wheel and pant to the landing gear with the included #4-40 bolts and nylon lock nut. Remember to slide the landing gear cuffs on before attaching both wheel pants as well. The screws holes should face towards the ground.
  • Page 8 This is what the finished assembly should look like. Make sure the wheel is centered in the pant. If adjustment is needed, you can rearrange the washers and collar to achieve it.
  • Page 9 Next attach the landing gear to the plane with the included 4mm bolts, washers, and nylon lock nuts. Use the Phillips head 3mm screw to attack the cuffs to the landing gear. The cuffs can also be used to hold the landing gear cover plate in place.
  • Page 10 Using a 3-32 allen wrench, be sure to make the already installed #4-40 bolts are tight. The 106” has a long tunnel suitable for canisters or tuned pipes. We provide the parts for a variety of setups. Vented covers are included for the tunnel which can be installed if desired. If using stock mufflers, the covering over the tunnel can be left intact if desired.
  • Page 11 Here are the included panels. There are various canister/pipe mounts included, drilling template, throttle servo box, and covers for various places on the airframe. Remove the covering over the vent holes on the cover plates as shown.
  • Page 12 Install the cover plates over the canister/pipe tunnel as shown using wood screws. This is a picture from the 104” Slick so the panels may look slightly different. Your kit includes two different kinds of ball links. The top one is used in between the phenolic control horns.
  • Page 13 Pushrods on the 106” are assembled in this way, with a ball link on each end of a stainless-steel link. Note that the links have left hand threads on one end and right hand threads on the other. Look very carefully to determine left and right before screwing on your links.
  • Page 14 The control horns on the EDGE are the double-phenolic fiberglass style. The horns for the elevators and ailerons are identical. The rudder horns are longer, double-sided. Elevator and Aileron horns are installed as follows: Using sand paper or something similar, rough up the areas that will be glued as shown.
  • Page 15 Locate the two slots and use a single control horn to make sure each of the two slots are cleaned out. Doing so will make installing the fully assembled horn much easier. Assemble the control horn as shown. Temporarily install in the control horn and cut out around the base of it as shown.
  • Page 16 The 106" Edge uses a pull-pull system for rudder servo location. Pull-pull cables are already installed in the fuselage for ease of installation of this system. View of the contents of the rudder hardware bag. Installing the rudder control horn: Assemble control horn as shown.
  • Page 17 Temporarily install the control horn, cut out around the base like we did for the aileron and elevator control horns. Once the covering is removed below the base plate, leave the horn in place and attach the other ball link. Next, push the control horn in the slot in one direction until you can see the holes in the center.
  • Page 18 Once the glue has set, install the rudder onto the fuse using the included hinge pin. Install rudder onto vertical stabilizer and fuselage, slide rudder hinge wire into rudder from the top and down into the recess slot on top of rudder as shown.
  • Page 19 Install collar onto rudder hinge wire at bottom. Trim wire as needed. Pull-pull cables are already installed into your fuselage. Complete rear end of pull wires on both sides as shown, using double crimps and looping wire through crimps as shown.
  • Page 20 Cross the pull-pull wires once inside the fuselage to form an “X” and complete the front end of the cables also with double crimps. A typical servo installation with one 3” double-sided offset arm is shown. Make cables snug, but not “banjo-string” tight. Only snug is necessary. Match your servos properly according to the instructions of your radio equipment.
  • Page 21 Install your elevator servo into the horizontal stab of your choice as shown. Yes, this will take some time and you will need a long screwdriver. Be patient.
  • Page 22 Parts included in elevator hardware bag. Install the servo arm and linkage as shown. You may want to lengthen the slot depending on which arm you choose to use. A 1.75” arm is used in this picture. Install both carbon stabilizer tubes into fuselage, and slide stabs on all the way. Attach with 4-40 screws and washers as shown.
  • Page 23 Included engine mounting hardware The location of the motor mounting bolts are etched into the firewall, but a template is included as well. This template is for DA twin cylinder engines and 3W.
  • Page 24 Template is shown here. Use tape to hold in place. Hole size is 1/4” Use large washers on the back along with the nylon lock nuts. Also shown here is the throttle servo mounted. You can used the included wooden servo rings to give the servo mounting screws more wood to bite into.
  • Page 25 The long standoffs plus one washer should give you the desired spinner to cowl gap. An extra washer may need to be added, or this washer can be removed depending on the spinner gap you prefer. DA-100 and DLE-111 mounted with shorter standoffs.
  • Page 26 Included throttle linkage parts. NOTE: The link length included is approximate, it works well on DA- 100 and DLE-111, for DA-120 which mounts farther forward, you may need a longer link for best geometry. Installing link.
  • Page 27 NOTE: A choke servo location is supplied on the bottom of the engine box AND a separate box-type servo mount is included in the kit to allow you to mount a choke servo in any location. However, we use and recommend a simple manual pull-type choke linkage which extends through the bottom of the cowl.
  • Page 28 In this build we decided to close off the tunnel and cut cooling slots in the bottom of the cowling.
  • Page 29 Here is an example layout of the throttle and fuel line setup. WARNING: make sure that the fuel line cannot come into contact with the muffler. In the picture above, we used flame retardant heat shrink over the tubing just in case it would ever touch the muffler. Next attach the bottom half of the cowling using the included #4-40 screws and washers.
  • Page 30 Note: We also highly recommend baffles to direct airflow over large electric motors and twin cylinder gas engines. Below is an example of what this baffling may look like. We recommend using balsa, or Depron foam.
  • Page 31 Here is an example manual choke setup using a spare pushrod.
  • Page 32 Here is an example layout of the RXs and where the RX packs would go.
  • Page 33 NOTE: There are three servo locations in each wing panel. You can use one servo in the center location, two in the inner and outer locations, or three servos. Be *extremely careful* if using only one aileron servo, most twin-cylinder engines 100CC and up produce enough power to blow back or even a flutter a single aileron servo.
  • Page 34 The wings are attached using a 6mm nylon bolt and spring clip. The first few times you install the wings, the holes for the spring clips will be tight to the fuselage side. This is by design, use a small tool to clearance this fit before installing the clip.
  • Page 35 The canopy hatch is supplied with the floor pre-installed. The rear of the hatch is left open so you can easily install a pilot head and cockpit control panel. When you have completed any work inside the cockpit, use a small amount of CA glue to install the balsa rear plate onto the canopy hatch. The canopy hatch is held onto the fuselage with 3mm nylon thumbscrews.
  • Page 36 The preferred CG for this plane is at 5.5” back from the leading measured at the wingtip. This is the recommended CG to start with and can then be tuned for a specific style of flying. 3D Hobby Shop wishes you the very best with your new 106” Edge!