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150 to 200cc Edge540 and 540T ARF
Instruction Manual
Congratulations and thank you for purchasing the Performance Aircraft Unlimited 43% Edge 540. 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 that puts out more than 300hp.
Made from modern composites, this aircraft is sure to be on the podium for some time to come.
The PAU Edge is no different! Designed with 2963 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. Just as it's full-scale counterpart,
the PAU Edge has found victory in competition aerobatics.
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Table of Contents
Related Manuals for PAU Edge540
Summary of Contents for PAU Edge540
- Page 1 Made from modern composites, this aircraft is sure to be on the podium for some time to come. The PAU Edge is no different! Designed with 2963 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.
- 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
12 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: 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 4.5”... - Page 7 First you’ll need to nock out the plywood opening the canister tunnel. Use a hobby knife on the small area not cut with a laser and lightly tap it out with a small hammer. Install the landing gear to the fuselage using the four 8/32 bolts, spring washers, and flat washers, and compression nuts.
- Page 8 Cut out the center wheel opening on the wheel pants on the side with the wood-mounting block. With the aircraft resting on the landing gear, we are going to need to set the right angle for the wheel pants. We used a standard servo and placed it at the end of the pant resting the end on the rubber grommets of the servo.
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Page 9: 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 4 6/32 bolts with two sealing washers Not Provided: Drill and small drill bit for wood... -
Page 10: Chapter 5 Engine Installation
Chapter 5 Engine Installation Your kit comes with both a firewall pre-mounted and an extra firewall for DA-200 installation. You can choose 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. -
Page 11: Chapter 6 Split Cowling Installation
Chapter 6 Split Cowling installation Place an “× × × × ” to ensure task completion: What you will need in this chapter: Fuselage and cowling Six 6/32 bolts with spring and lock washers 12 button head 6/32 bolts and nylon washers (split cowl) Not Provided: A 5”... -
Page 12: 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 Provided 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 13 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 14: 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 15 First you need to find the pre-drilled holes for the steel posts. Install the aluminum control horn assemblies to each surface with the M4 bolt in the down position. Use blue loc-tite on the aluminum base to ensure the bolt does not try to back out under vibration. Screw on the horns on to the posts. Do not use loc-tite installing the horn.
- Page 16 Find the pre-drilled hard point, remove the covering and insert the longer 6” stainless treaded rod provided and discard the 4” rod. Install the Dubro fasteners to the rod. Use loc-tite as shown if you are not planning on using the lock nuts.
- Page 17 fitting in the carburetor line that connects to your fuel dot or fueling device. Make sure you use Tygon fuel tubing inside the tank for the clunk as well. Install the fuel tank just in front of the wing tube using zip-ties or hook and latch (Velcro) straps. Place a loop in the vent line over the top of the tank to prevent fuel loss during flight and improve flight times.
- Page 18 Check CG at this time and place your batteries and remaining hardware in locations to attain the desired CG. If satisfied mount your remaining hardware. Congratulations! You have just completed assembly of your Edge540 and or 540T. Now would be a good time to install the optional vinyl graphics included with your kit.
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Page 19: Chapter 9 Radio And Control Surface Setup
Chapter 9 Radio and Control Surface Setup Now we are ready to setup your aircraft for flying. Included is this manual are templates for measuring surface throw you may use if desired. We recommend that you setup your aircraft on low rates for initial flights until you become familiar with the aircraft and its capabilities. -
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. Inspect the airframe for any visible damage and loose covering that may have occurred during the build. - Page 21 For contest flying such as IMAC, 8” CG offers great precision and our airframe is a great choice. We hope this aircraft offers you many years of enjoyment. Thank you again for choosing PAU and look for exciting future products.
- Page 22 Throw Template If printing from Adobe, turn off page scaling. Cut out around all the dotted lines.
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