Hangar 9 EDGE 540 Instruction Manual
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Hangar 9 EDGE 540 Instruction Manual

Hangar 9 EDGE 540 Instruction Manual

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EDGE
EDGE
EDGE
EDGE
EDGE
EDGE
Ultra Aerobatic 1.20 ARF
INSTRUCTION MANUAL
Specifications
Wingspan:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Length:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wing Area:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight (Approx.):
Recommended Engines: 1.08 –1.50 2-Stroke
• 90% prebuilt
• High-quality hardware included
• Precovered in genuine Goldberg UltraCote
• Prefinished fiberglass cowl and wheel pants
'' 198.10 cm
78
''
68.5
174 cm
1010 sq. in 651.6 dm
11-13 lbs
5-5.9 kg
. . . . . . . . . . . . . . . . . . . .
1.20 –1.80 4-Stroke
TM
TM
540
540
2
®
90
%
PRE-BUILT

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Summary of Contents for Hangar 9 EDGE 540

  • Page 1 EDGE EDGE EDGE EDGE EDGE EDGE Ultra Aerobatic 1.20 ARF INSTRUCTION MANUAL • 90% prebuilt • High-quality hardware included ® • Precovered in genuine Goldberg UltraCote • Prefinished fiberglass cowl and wheel pants Specifications ′′ 198.10 cm Wingspan: ........′′...

  • Page 2: Table Of Contents

    Section 15. Installing the Control Linkages (Rudder/Elevator/Throttle) Section 16. Attaching the Cowling Section 17. Mounting the Hatch (with Canopy) Section 18. Adding Decals Section 19. Balancing the Edge 540 Section 20. Control Throw Recommendation Set-up & Flying by Mike McConville Preflight at the Field...

  • Page 3: Introduction

    Thank you for purchasing the Hangar 9 Edge 540. This is the latest aerobatic line of fine ARFs (Almost-Ready-to-Fly) produced by Hangar 9. The Edge 540 is a high-performance aircraft best suited for the more experienced flyer and modeler. Although this is an ARF, it does have some construction features that can be challenging for a new modeler.

  • Page 4: Tools And Supplies Required (Not Included In Kit)

    Tools and Supplies Required Adhesives Thin CA (Cyanoacrylate) glue Masking tape Thick CA (Cyanoacrylate) glue Threadlock Z-42 (Pacer) 6-Minute Epoxy (HAN8000) Canopy Glue (Pacer PAAPT56) 30-Minute Epoxy (HAN8002) Silver Solder (Staybrite) Tools Drill Epoxy brushes Drill bits: 1/16'', 1/18'', 5/32'', 1/14'' Scissors Soldering iron Straight edge...

  • Page 5: Contents Of Kit

    Contents of Kit Large Parts Fuselage (HAN1351) Left Wing Half with Aileron (HAN1352) Right Wing Half with Aileron (HAN1352) Vertical Stabilizer with Rudder (HAN1353) Horizontal Stabilizer with Elevator(s) ( HAN1353) Cowl (HAN1354) Wheel Pants (HAN1355) Hatch (HAN1358) Other Parts Main landing gear (HAN1356) Wheels (2) (HAN2027) Fuel tank and hardware (HAN1460) Trim sheets (HAN1359)

  • Page 6: Section 1. Hinging The Ailerons

    CA glue. Step 1. Carefully remove the aileron from one of the wing panels. Note the position of the hinges. The Edge 540 comes with high-quality CA-type hinges. Step 2. Remove each hinge from the wing panel and aileron and place a T-pin in the center of each hinge.
  • Page 7 Section 1: Hinging the Ailerons CONTINUED Sealing the Hinge Gaps It’s imperative that the aileron and elevator hinge lines be sealed airtight to prevent flutter. Sealing the hinge line has several advantages. A sealed hinge line gives a greater control response for a given control deflection.
  • Page 8 Section 1: Hinging the Ailerons CONTINUED Sealing the Hinge Gaps (continued) Step 14. Fully deflect the aileron in the up position. Place the straight edge over the hinge line covering that you just ironed down in Step 5 with the edge of the straight edge placed firmly at Step 11.

  • Page 9: Section 2. Joining The Wing Halves

    Section 2: Joining the Wing Halves Parts Needed Tools and Adhesives Needed • 30-minute epoxy • Rubbing alcohol • Right/left wing panels • 6-minute epoxy • Paper towels • Dihedral brace • Mixing stick • Wax paper • Plywood wing dowel plate •...
  • Page 10 Section 2: Joining the Wing Halves CONTINUED Step 7. Apply a generous amount of epoxy into the other wing Step 9. Carefully slide the two wing halves together and firmly panel cavity. press them together, allowing the excess epoxy to run out. There should not be any gap in the wing halves.
  • Page 11 Section 2: Joining the Wing Halves CONTINUED Step 14. Locate the yellow and blue center trim tape. Apply a portion to the center of the top and bottom of the wing center after the epoxy has cured from Step 13. Step 11.

  • Page 12: Section 3. Installing The Aileron Servos

    Section 3: Installing the Aileron Servos Parts Needed Tools and Adhesives Needed • Hobby knife • Left/right wing halves • Phillips screwdriver • Servos (2) • Drill • Servo extension(s) (2-12” recommended) • Drill bit: 1/16” • Y-harness (if using a non-computer radio) •...
  • Page 13 Section 3: Installing the Aileron Servos CONTINUED Step 6. Use a piece of string with a small weight (bolt from Step 9. Repeat the procedure for the other wing half . engine mounting hardware) attached as a device to attach to one end of the servo lead extension and thread through the servo Note: If you are using a non-computer radio, it will be opening, through the wing, and out the servo lead exit.

  • Page 14: Section 4. Installing The Aileron Linkages

    Section 4: Installing the Aileron Linkages Parts Needed Tools and Adhesives Needed • Wing assembly from Section 2 • Phillips screwdriver • Left control horn • Drill • Right (reversed) control horn • Drill bits: 1/16”, 3/32” • Plastic plate (2) •...
  • Page 15 Section 4: Installing the Aileron Linkage CONTINUED Step 6. Use a 3/32” drill bit to drill the screw holes for Step 8. Repeat the process for the other aileron on the other mounting the control horn. We suggest you apply a thin coat of wing panel.

  • Page 16: Section 5. Mounting The Wing To The Fuselage

    Section 5: Mounting the Wing to the Fuselage Parts Needed Tools and Adhesives Needed • Hobby knife with #11 blade • Pliers • Wing • Ruler • 30-minute epoxy • Fuselage • Drill • Epoxy brush • Wing hold down hardware •...

  • Page 17: Section 6. Installing The Tail (Vertical And Horizontal Stabilizers)

    Section 5: Mounting the Wing to the Fuselage CONTINUED Step 7. Once the blind nuts are in place, trial fit the wing onto the fuselage and insert the nylon mounting bolts. Tighten enough to hold the wing in place but do not completely tighten. Check the alignment of the wing to the reference point on the fuselage again as done in Step 2.
  • Page 18 Section 6: Installing the Tail CONTINUED Step 2. Trim away the covering over the elevator and rudder linkage openings on both sides of the fuselage at the tail. Look carefully, and you will see the slots. Trim away the covering using a sharp hobby knife.
  • Page 19 Section 6: Installing the Tail CONTINUED making sure you align it with the reference marks made Caution: Do not cut into the wood below the covering. previously. Then align the stab so that it is square with the wing This will weaken the structure. when sighted from the front.

  • Page 20: Section 7. Hinging The Horizontal Stabilizer And Elevator(S)

    Section 6: Installing the Tail CONTINUED Step 11. Carefully check the alignment of the vertical stabilizer to the horizontal stabilizer. A 90-degree triangle is helpful here. Use masking tape to hold the components in alignment. Allow the epoxy to dry completely cured. Section 7: Hinging the Horizontal Stabilizer and Elevator(s) Fuselage...

  • Page 21: Section 8. Hinging The Rudder And Installing The Tailwheel

    Section 7: Hinging the Horizontal Stabilizer and Elevator(s) CONTINUED Step 3. After the hinges are dry, check that they are securely in Step 4. Repeat steps 1-3 for the other elevator half place by trying to pull the elevator from the horizontal stabilizer. Step 5.
  • Page 22 Section 8: Hinging the Rudder and Installing the Tail Wheel CONTINUED Step 5. Using a hobby knife or a Moto-tool, cut a slot or groove into the back of the fuselage vertical stabilizer as marked in Step 3. This groove will be used to accept the tail wheel pivot bushing.

  • Page 23: Section 9. Installing The Rudder And Elevator Control Horns

    Section 8: Hinging the Rudder and Installing the Tail Wheel CONTINUED Step 8. With the rudder aligned (up and down), apply thin CA Step 9. Work the rudder right and left. Check for free movement glue to the rudder hinges on both sides of the rudder, using the and ensure that the tail wheel tracks accordingly.
  • Page 24 Section 9: Installing the Control Horns CONTINUED Step 3. Locate the standard control horn. Trial fit the horn on Step 6. Carefully install the screws and engage the plastic plate the elevator with the flat part towards the tip of the elevator and on the other side.
  • Page 25 Section 9: Installing the Control Horns CONTINUED Step 9. Drill the holes using the same technique as described Step 10. Mount the two horns on the rudder, one on either in step 5. Use caution not to damage the covering. side, with the standard horn on the left side and the reverse horn on the right side.

  • Page 26: Section 10. Mounting The Main Landing Gear

    Section 10: Installing the Main Landing Gear Parts Needed Tools and Adhesives Needed • Fuselage • Hobby knife with #11 blade • Main landing gear • Phillips screwdriver • Mounting hardware • Felt-tipped pen or pencil • Locktite Z-42 ® Step 1.

  • Page 27: Section 11. Assembling And Mounting The Wheel Pants

    Section 11: Assembling and Mounting the Wheel Pants Parts Needed Tools and Adhesives Needed • Ruler • Rubbing alcohol • Wheel pants • Phillips screwdriver • Paper towel • Wheels (2) • Round file (fine) • Drill bits: 1/4'', 3/32'', 1/8'', 1/2'' •...
  • Page 28 Section 11: Assembling and Mounting the Wheel Pants CONTINUED Step 9. The wheel pant can be trial fitted to the landing gear/axle. You may find you will have to open up the large axle hole a bit with a round file due to epoxy seeping into the opening.

  • Page 29: Section 12. Installing The Engine (2/4 Stroke)

    Section 12: Installing the Engine Parts Needed Tools and Adhesives Needed • Phillips screwdriver • Fuselage • 30-minute epoxy • Metal motor mounts • Rubbing alcohol • Mounting hardware • Epoxy brush • Engine • Mixing stick • Spacer Plate (If using MDS 1.48) •...

  • Page 30: Section 13. Assembling And Installing The Fuel Tank

    Section 13: Assembling and Installing the Fuel Tank Parts Needed Tools and Adhesives Needed • Hobby knife with #11 blade • Clunk (Fuel Pickup) • Phillips screwdriver • Tube (vent) • Tubing bender (optional) • Tube (fuel ) • Tubing cutter (optional) •...
  • Page 31 Section 13: Assembling and Installing the Fuel Tank CONTINUED Step 5. Locate the piece of silicone fuel tubing and metal clunk. Step 8. Carefully insert the stopper into the fuel tank. Position This tubing will be attached to the clunk making up the fuel the stopper so the vent tube is pointing to the top of the fuel tank.

  • Page 32: Section 14. Installing The Radio

    “U” location. Allow the epoxy to cure completely. Note: We recommend 1 '' servos arms for the rudder and elevator. If you are going to use 3-D throws, Hangar 9 offers a variety of heavy duty gold-anodized machined aluminum servo arms for 3-D flying. (HAN3576-3579) Step 2.
  • Page 33 Section 14: Installing the Radio CONTINUED Step 5. Remove the servos and drill the 12 holes using a Note: We wrapped the battery in foam and attached it to the '' drill bit. Remount the servos and screw in the mounting plywood above the fuel tank directly behind the screws provided with the servos.

  • Page 34: Section 15. Installing The Control Linkages (Rudder/Elevator/Throttle)

    A groove can be cut from the holes piece of heat shrink tubing. Since the Edge 540 uses a split (two- to the end of the wood push rod to help secure the rods in place piece) elevator, you will construct a pushrod that has two when applying epoxy.
  • Page 35 Section 15: Installing the Control Linkages CONTINUED Step 5. Make a 90-degree bend at the opposite (unthreaded) Step 10. Slide the elevator pushrod through the hatch opening end of each 12'' rod at the positions marked in Step 4. Trim the in the fuselage and into the tail section so that each rod exits at bend section to a length of 1/8'' to 3/16'' (enough to fit in the hole the rear of the fuselage, through the elevator linkage slots.
  • Page 36 Final adjustments can be made at either or both ends of the linkage by screwing in or out the clevis as needed. Hangar 9 offers a varitey of heavy duty, gold anodized machined aluminm servo...

  • Page 37: Section 16. Attaching The Cowling

    flow. A template for the cowl opening is also provided. Step 2. Make a template of the cylinder head of the engine you are going to mount in the Edge 540. Mount the engine and place the template over it. Use a piece of cardboard or heavy paper that can be taped to the fuselage and folded back.
  • Page 38 Note: On some engines where the carburetor is not easily sure it fits correctly. There should be ample clearance (1/8'' accessible, a a fuel dot can be used. Hangar 9’s gold around the engine and muffler). Make sure the prop hub is anodize machined aluminum fuel dot with “T”...

  • Page 39: Section 17. Mounting The Hatch (With Canopy)

    They will be Step 4. If you plan on using a pilot in your Edge 540, now is covered by plastic, so you will have to look carefully for them. Once the time to mount it to the cockpit floor area of the hatch.
  • Page 40 Section 17. Mounting the Hatch (with/canopy) CONTINUED Step 5. Locate the canopy and note the trim lines. Carefully Step 7. After confirming the fit of the canopy to the hatch, attach trim out the canopy using Lexan ® scissors or regular scissors. it to the hatch using canopy glue such as Pacer 560.

  • Page 41: Section 18. Adding Decals

    Step 3. Next, apply the Hangar 9 decal to the wheel pants. Step 6. The “Edge 540” decal is applied to the top of the wing, the “Edge” decal is applied to the left wing panel, and the “540”...

  • Page 42: Section 19. Balancing The Edge 540

    3-D rates or flutter can occur. flights, then increase the throws to your liking. The 3-D rates allow the Edge 540 to perform the new generation of aerobatic maneuvers, such as waterfalls, elevators and harriers. However, they also make the model very sensitive. It is recommended that the 3-D rates be tried only after becoming familiar with your Edge 540.

  • Page 43: Set-Up & Flying By Mike Mcconville

    Setup and Flying by Mike McConville The Edge 540 performes well in both precision and wild 3-D The Prototype Model Setup aerobatics. The unique straight leading edge of the wing gives it extrodinary low-speed handeling. We’ve found this new Edge to All of the recommended settings in this manual are a result of the fly as precise as a “Pattern”...
  • Page 44 Setup and Flying by Mike McConville CONTINUED to get it perfect. When its right, the Edge should fly straight when talking about?” to you. It took me quite a while to figure this out. on knife edge and not roll at all or track to the top or bottom of Let’s back up to how we all learned to do a snap roll.
  • Page 45 The same applies, but not to the same extent, with rudder and ailerons. When it comes to 3-D aerobatics, our Edge 540 is second to none. The Maneuvers Let’s cover the seven 3-D maneuvers where the Edge really excels.
  • Page 46 Setup and Flying by Mike McConville CONTINUED Advanced recovery: Take the elevator all the way to the The Elevator ground—adding some power before it touches down to slow the decent and transition into a Harrier and land. Add power to get the nose to rise to vertical and transition into a Torque Roll.
  • Page 47 Setup and Flying by Mike McConville CONTINUED The Waterfall The Torque Roll What it is: The Edge “hovers” vertically in place, rotating left around its roll axis. The “in-line” midwing configuration of the Edge makes it one of the easiest Torque rollers around. Setup: Full 3-D throws in elevator and rudder are a must.
  • Page 48 Setup and Flying by Mike McConville CONTINUED The Parachute The Wall What it is: The Parachute or Terminator is a vertical dive that What it is: The Wall is a Parachute turned on end. The instantly decelerates in its descent as it instantaneously corners model starts in normal level flight and suddenly corners nose up into an Elevator.

  • Page 49: Preflight At The Field

    Preflight at the Field Range Test Your Radio Adjusting the Engine Step 1. Before each flying session, be sure to range check Step 1. Completely read the instructions included with your your radio. This is accomplished by turning on your transmitter engine and follow the recommended break-in procedure.

  • Page 50: Ama Safety Code

    AMA Safety Code Offical AMA National Model Aircraft Safety Code Effective January 1, 1999 Model flying MUST be in accordance with this Code in order for AMA Liability Protection to Apply General I will not fly my model aircraft in sanctioned events, air shows, or model flying demonstrations until it has been proven airworthy by having been previously, successfully flight tested.

  • Page 51: Radio Control

    AMA Safety Code CONTINUED Radio Control I will have completed a successful radio equipment ground range check before the first flight of a new or repaired model. I will not fly my model aircraft in the presence of spectators until I become a qualified flier, unless assisted by an experienced helper. I will perform my initial turn after takeoff away from the pit or spectator areas, and I will not thereafter fly over pit or spectator areas, unless beyond by control.
  • Page 53 Template Cut-Out of Cowl Bottom MDS 1.48...
  • Page 56 © 2000, Horizon Hobby, Inc. www.horizonhobby.com...

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