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100cc Edge 540 and 540T ARF
Instruction Manual
Congratulations and thank you for purchasing the Performance Aircraft Unlimited 36% Edge 540 or 540T. The
Zivko Edge 540 was designed and developed to be the best aerobatic aircraft in the world and it delivered! Not
only does this aircraft dominate IAC competition but has also found a home in the Red Bull racing circuit where
it has won title after title. The 540 stands for the powerful Lycoming 540 motor, which puts out more than
300hp. Made from modern composites, this aircraft is sure to be on the podium for some time to come. The
Edge 540T is a two place tandem configuration.
The PAU Edge is no different! Designed with 2123 sq inches of wing area while keeping the total weight down
has made this aircraft a true performer. All wood construction and top quality hardware make it hard to beat. If
you want an aircraft precise enough to compete in IMAC or to turn it loose for the wildest 3D maneuvers on the
planet, the 36% PAU Edge's are the only choice. PAU has also increased the aileron size and really beefed up
the wings. The fuse is redesigned and now accepts the DA-120 and has a much more aggressive stance. More
side area and stubble surface changes clean this aircraft up further in knife.
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Summary of Contents for PAU Edge 540
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Page 1: Instruction Manual
Congratulations and thank you for purchasing the Performance Aircraft Unlimited 36% Edge 540 or 540T. The Zivko Edge 540 was designed and developed to be the best aerobatic aircraft in the world and it delivered! Not only does this aircraft dominate IAC competition but has also found a home in the Red Bull racing circuit where it has won title after title. - Page 2 We believe you will find this to be one of the finest flying aircraft on the market. Most modelers will find assembly of this aircraft simple and straightforward. We recommend the builder follow the step-by-step instructions to achieve the best performance and to ensure nothing was over looked. This manual also includes tip sections throughout that may help you in key areas during assembly.
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Page 3: Chapter 1 Parts Inventory
8 HD 4/40 Dubro ball links 1 Set of additional various marked hardware 1 Vinyl graphics package If any of these parts are missing immediately contact PAU. If you need more information you can visit our support forum at: www.flyinggiants.com... -
Page 4: Chapter 2 Preparation For Assembly
Chapter 2 Preparation for Assembly Professionals utilizing premium Ultracote covering carefully covered your model. Due to climate changes during shipping, the models covering may have loosened and/or winkled. It’s a good habit to go over your model with a covering iron to ensure all joints, seams, and edges are properly sealed. Ultracote is a lower temperature film that seals and shrinks at lower temperatures. - Page 5 Optional step Side windows and rear inspection glass. Included with you kit are optional lower pilot side windows and the rear inspection windows. This adds a nice touch to your aircraft and gives a little more scale uniqueness. Locate the windows in your kit. Using a sharp exacto knife, locate the window frames in the fuse and carefully cut through the covering and into the laser cut lines in the fuse.
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Page 6: Chapter 3 Landing Gear And Tail Wheel Assemblies
Chapter 3 Landing Gear and Tail Wheel Assemblies Now that we’re ready for assembly, we are going to start with the main landing gear first. You will need to locate the following parts to begin assembly. Place an “× × × × ” to ensure task completion: What you will need in this chapter for the main gear: Aluminum main gear One pair of 4 inch wheels... - Page 7 Now lets get the tail wheel assembly installed. Once the mains are on, find the pre-drilled holes for the tail wheel assembly. Install the tail wheel assembly with the 6/32 bolts using blue loc-tite. Install the steel tiller horn just behind the hinge line on the bottom of the rudder using the two small wood screws.
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Page 8: Chapter 4 Canopy And Fuselage Hatch
Chapter 4 Canopy and Fuselage Hatch Place an “× × × × ” to ensure task completion: Gather the following for canopy and hatch installation: Canopy Fuselage and Access Hatch 8 to 16 small wood screws Two 6/32 bolts with two sealing washers Not Provided: Drill and small drill bit for wood screws Canopy glue (optional) -
Page 9: Chapter 5 Engine Installation
Chapter 5 Engine Installation Your firewall is pre-mounted but our customers can select from a wide variety of engine choices. It is nearly impossible to cover every engine installation choice in this manual but we’ll cover a few. Your aircraft was designed around the 100 to 120cc twin gas motors. - Page 10 Also with the engine is installed, you will want inches from the firewall to the spinner back plate for 7-3/4 proper cowl placement. DA-100 installation The firewall is pre-marked so you'll just need to center your motor in the "+". Take a ruler and draw a line across the entire firewall for the thrust line and offset centerline.
- Page 11 DA-85 installation You will just need to center your motor in the "+". Take a ruler and draw a line across the entire firewall for the thrust line and offset centerline. DA-85 users only. If using the DA template provided on the last page of your DA manual, check the measurements on the template and ensure the holes are correct.
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Page 12: Chapter 6 Cowling Installation
Chapter 6 Cowling installation Place an “× × × × ” to ensure task completion: What you will need in this chapter: Fuselage and cowling Five 6/32 bolts with spring and lock washers Not Provided: A 4-½ inch spinner A Dremel tool A facemask and eye protection Pencil or dry erase marker Always wear a mask and eye protection while cutting fiberglass. -
Page 13: Chapter 7 Control Surface Installation
Chapter 7 Control Surface Installation Place an “× × × × ” to ensure task completion: What you will need in this chapter: Entire airframe Provide hinges Not Provided: 30 to 45 minute epoxy Two cycle oil 9. Now were going to prep the hinges for installation. Take a small drop of oil and place it in each of the pivot points of your hinges. - Page 14 14. Install the tiller springs you set aside in chapter 2 to the tiller horn and tiller. Tip#4 Optional step. After your epoxy has cured, it would be a good time to seal all of your hinge gaps prior to installing you hardware.
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Page 15: Chapter 8 Hardware Installation
Chapter 8 Hardware Installation We provide high quality aluminum control horn assemblies included with our latest generation of PAU aircraft kits. We believe these lightweight assemblies are the best available and can also be purchased separately from PAU. Place an “× × × × ” to ensure task completion:... - Page 16 Make sure your elevator servos are centered and mount your servo arms parallel to the hinge line. Take some masking tape and tape the elevator counter balances to the stabilizers so that they are in a center position. Screw in your two HD ball links onto the counterclockwise ends of the 2”...
- Page 17 Now add the control horns placing them at 2” from the hinge line. Install your pull-pull cable your remaining pull-pull hardware. Cables should be crossed to avoid any rubbing on the exits. It is normal for the non-pulling side of the cable to slacken a little when the rudder is deflected.
- Page 18 Install your throttle push rod. Again as mentioned earlier, we do not want metal-to-metal contact at the attachment point on the engine. Use a 4/40-rod with a 2/56 ball link for 4/40 rod to attach the push rod to the motor. Once satisfied with your throttle setup, mount the cowl using the five 6/32 bolts provided and attach the prop and spinner.
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Page 19: Chapter 9 Radio And Control Surface Setup
Now we’re ready to check the CG and install your remaining hardware. The CG range is 6 to 7 inches back as measured where the wing meets the fuselage or right on the center of the wing tube. We recommend 6-1/2 inches for initial flights. -
Page 20: Chapter 10 Final Inspection And Pre-Flight
Chapter 10 Final Inspection and Pre-Flight Welcome to the final chapter prior to your maiden flight. We hope you have enjoyed building your Edge 540. Lets go over the airframe and perform a pre-flight to make sure everything is in order. - Page 21 Understanding and applying these few safety and maintenance guidelines will help you get many enjoyable and rewarding flights with your Giant Scale Plane. We hope this aircraft offers you many years of enjoyment. Thank you again for choosing PAU and look for exciting future products.
- Page 22 DA-100 Template If printing from Adobe, turn off page scaling.
- Page 23 Throw Template If printing from Adobe, turn off page scaling. Cut out around all the dotted lines.