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Composite-ARF Edge 540 2.6m Assembly Manual

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Summary of Contents for Composite-ARF Edge 540 2.6m

  • Page 2 Introduction to the Edge 540 Congratulations on acquiring your new Composite Arf 2.6m Edge 540! Here at Composite Arf we endeavour to bring you the best model aircraft possible, built with modern and innovative techniques. The Edge 540 is constructed using our revolutionary Total Area Vacuum Sandwich (TAVS) technology.
  • Page 3 For this reason we at Composite-ARF are unable to guarantee or provide a contractual agreement with any individual or company that the model you have made will function correctly and safely.
  • Page 4 Servo arms: The longer the servo arm the more pressure there is on the servo. If you are not into full 3D consider using 1.25” arms, you will still get plenty of surface travel, just not the extreme movement. Extreme surface travel is mostly only handy for post stalled manoeuvres like rolling harriers, very flat spins and the likes.

  • Page 5: Build Requirements

    Build Requirements Additional Components: § Engine. 100cc-120cc twin cylinder. (DA120 used in this manual) Stand off’s. 2” plus is required. (SWB 2” to 2 7/16 stand off’s were used in this manual) § Exhaust We strongly suggest the use of canister mufflers, obviously a lot is dependent on your engine selection, the following types will fit easily to the Edge.

  • Page 6: Tools Required

    Tools Required You will not require any specialized tools to build your Edge 540. However some items make the job a little easier, such as a tapered reamer (RC car body reamer), a step drill bit and a centre drill bit. These items make drilling holes in the composite materials less problematic, and very simple.

  • Page 7: Landing Gear

    Landing Gear It’s easier to fit the landing gear as the first step, you will find it easier to handle the model when it’s on its wheels. Drilling the legs is easier if you have a pedestal drill, and a No 3 centring drill bit.
  • Page 8 Wheel Pants: The wheel pants are recessed to fit against the carbon undercarriage legs, you will need to epoxy in place the “U” shaped milled plywood pieces to the inside of the wheel pants. Rough up the inner surface of the wheel pant with some sand paper, prior to applying epoxy.
  • Page 9 Tailwheel Assembly: When fitting the tailwheel assembly, the choice of wire style, or carbon leaf style, is completely up to your personal preference. You will find there is plenty of area behind the stern post to accommodate almost all types of commercially available tailwheel assemblies.
  • Page 10 Cowl Parts Required: § Cowl Assembly § Fuselage Parts Bag Tools Required: § Electric Drill § Drill Bit 3mm § 3mm Hex driver § Steel rule(s) § Tape Measure § Masking tape § Marking pen § Epoxy (30min or Hysol) The mounting of the cowl is one area where you should take your time, don’t rush this.
  • Page 11 Now that both the top and bottom halves of the cowl are joined, it’s time to mount the complete assembly to the fuselage. Align the cowl on the fuselage and check the fit. Now is the time to make any small adjustments if necessary.

  • Page 12: Engine Installation

    Engine Installation Parts Required: § Cowl Assembly § Fuselage Parts Bag § Standoffs. 2 SWB adjustable stand off s Tools Required: § Electric Drill § Drill Bit various § Square (rule) § Steel rule(s) § Level § Masking tape § Marking pen The engine installation requires that the cowl assembly be fitted first.
  • Page 13 A DA100/120 has a bolt separation pattern of 70mm across and 80mm from top to bottom. Make your marks as shown in the picture above. When you are satisfied with your engine position markings, drill your mounting holes. Drill a 3mm pilot hole first, then use a 7mm drill bit to enlarge the hole to suit the 6mm T-nut.

  • Page 14: Exhaust Installation

    Exhaust Installation Parts Required: § Exhaust System. (KS86V, MTW TD75 etc) § Headers. (KS Comfort Headers, MTW Knuckle headers etc) § Canister Mounts Tools Required: § Electric Drill § Drill Bit various § Dremel tool § Square (rule) § Steel rule(s) §...
  • Page 15 Ignition and battery mounting At this point in the assembly process it pays to think about where you wish to place your ignition, ignition battery, kill switch and receiver batteries. If you are using one of the current crop of light weight engines such as the DA120 (2.25kg), you will need to place as much of the on board weight as far forward as possible to obtain the required C of G.
  • Page 16 Once you have your ignition/battery tray assembled and trimmed to fit neatly inside the engine dome, tack it in place with CA and kicker. Make sure you are satisfied with the position of everything, and that the throttle servo is correctly placed. When you are fully satisfied, epoxy in place (don’t forget to lightly sand the area first.
  • Page 17 Horizontal Stabilisers and Rudder Parts Required: § Stabs, elevators and rudder § Stab parts bag § Elevator servo § Alloy Servo Arm (SWB, Secraft, Hanger 9 etc) 1.25 -1.5 Tools Required: § Dremel tool § X-Acto hobby knife § Square (rule) §...
  • Page 18 measure your servo and servo arm to make sure the measurements suit your needs. If not make the necessary adjustments. Cut out the marked out area using your Dremel tool with a cut off wheel or burr. You can also use a sharp X-Acto hobby knife. Take your time if using a Dremel! Mount your servo using the 2.9mm sheet metal screws provided.
  • Page 19 The stab tube is already complete and ready for you to use, no more needs to be done other than fit the tube to the stabs. The retention bolts have been pre fitted for you, and only requires you to fit the stabs to the fuselage. The stab tube may already be marked with L and R, to help you distinguish the correct orientation.
  • Page 20 Ailerons The ailerons on the Composite Arf Edge 540 differ from what has been up to now, normal for Composite Arf models, the ailerons are centre hinged! The ailerons now use a hinge tube just like the rudder and elevators. The ailerons are huge, and require 2 brass hinge tubes, to cover the length of the aileron.
  • Page 21 servo mount. Don’t forget to give the surface of the hatch a light sand before applying the epoxy. Set aside and allow epoxy to set. Now your servo hatches are complete, and you can now fit them to the wing. Sit the hatch in place and hold them there with some masking tape while your pre drill the holes for the hatch retaining screws Use a small drill bit (1.5-2mm) to drill the holes for the hatch cover retention screws.
  • Page 22 Canopy Parts Required: § Canopy Tools Required: § Masking Tape § Marking pen § Scissors § Canopy Adhesive Clear Silicon (Silastic) § Syringe 30ml Fitting the canopy is one of the areas that people seem to dislike! Really it’s not that difficult, and the Edge canopy is quite small, and fits in place beautifully.
  • Page 23 It’s important that you fit the canopy while the canopy frame is attached to the fuselage, this will keep the frame properly aligned and not twisted. Masking tape is used to hold the canopy in position prior to gluing. It may pay to have another pair of hands available to assist you here.
  • Page 24 Rudder Servo(s) Parts Required: § Rudder tray components § Rudder parts bag § Phenolic servo arms § Rudder Servo(s) JR DS8911, DS6301 or DS6311HV Futaba S9157 or BLS152 § Alloy servo discs § Alloy Servo Arms (optional) SWB 4.5 Full arm, plus 3 Full arm (front servo) SWB or Secraft turnbuckles 50mm (2 ) Tools Required: §...
  • Page 25 If you need to move the rudder tray forward to obtain the correct C of G, you will need to make 2 new mounting formers to use on the existing tray. Use 3mm ply for this. Use some card to make the shapes for the new formers. You can use the supplied former to aid with the basic shape.
  • Page 26 Place some masking tape on the fuselage roughly where your mark will be. With the straightedge on the canopy seat mark a line using the measurement you just established. Now that you have the servo arm position marked on the outside of the fuselage, you can use a string line to mark the horizontal cable line.
  • Page 27 When you are satisfied that the cable exit slot is positioned correctly, make a cut with your Dremel and cut off wheel. The cut off wheel will cut the fuselage material with ease, so keep the tool steady. You should now make up your pull/pull cables. Start by doing one end only.
  • Page 28 Fuel Tank and Tray Parts Required: § Wooden Tank Tray Components § Plywood Tank Tray Saddle Components § Tank Tray parts bag § Fuel Tank DuBro 32oz § Tygon Fuel Line Tools Required: § Steel rule(s) § Marking pen § Ball Driver(s) Fitting the fuel tank tray should be one of the last things you do when assembling the Edge 540.
  • Page 29 With the wing tube in position trial fit the tank tray and saddle. It’s important that you position the tray so as the top of fuel tank does not hit the canopy frame. There is not a lot of room to spare, so take your time obtaining the correct angle.
  • Page 30 Run your fuel line to the engine taking care to ensure that it doesn’t rub against the fibreglass or plywood structures. Where you run the fuel line is partially dependant on which engine you choose, and exhaust system fitted. Please view the pictures below for where the fuel and vent lines were run during our build. All of our fuel lines were held in place with self adhesive clips and where the line passed through the fuselage rubber grommets were used.
  • Page 31 Engine cooling and vents It is important to keep your engine cool, regardless of the engine manufacturer. Keeping your engine cool is good practice, your engine will like love for it! Another area you must also consider is the fuselage. If you are running canisters or tuned pipes this is a must! We will show you how we ducted the air to the DA120 that we used.
  • Page 32 To ventilate the fuselage you will need to cut some cooling slots. The fuselage material is easy to cut out, using your Dremel. Finishing with a sanding drum will keep the process simple and tidy. Where you place the slots is again dependent on the final fit out and components used.

  • Page 33: Control Throws

    C of G and Control Throws The centre of gravity position of the Edge 540 is 140mm from the leading edge of the wing. As the wing has a straight leading edge, it is irrelevant where on the leading edge you measure from, but at the tip is probably the easiest.
  • Page 34 Alternatively you can contact us via the emails below. We also welcome your feedback, please contact us if you would like to see something added or altered. We are always looking to improve our products and the information we supply. Technical support; techsupport@composite-arf.com Feedback; feeback@composite-arf.com www.carf-models.com Edge 540-2.6m manual V1 (April 2011)