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Extreme Flight 3DHobbyShop Edge 540 Assembly Manual

92" airframe
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Assembly Manual / Airframe – 92" 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.
•
A lways 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.
1

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Summary of Contents for Extreme Flight 3DHobbyShop Edge 540

  • Page 1 Assembly Manual / Airframe – 92” 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 Landing gear User blue loctite to lock all of the set screws on the tailwheel assembly and re-tighten them. Attach the tailwheel to the bottom of the fuse as shown with 3 x 3mm screws and washers. Use blue loctite on these screws. Main Wheels: Place one wheel collar over the axle, then the main wheel, then the other collar and tighten as shown.
  • Page 5 Slide the landing gear-to-fuselage fairings onto the landing gear legs. Insert the wheels/axles into the wheel pants and install onto the landing gear legs. Tighten the axle nuts. Install wood screws as shown through the gear legs into wheel pants.
  • Page 6 Attach the main gear to the fuselage using 4 x 4mm screws, washers, and locknuts. Note that you will need to use a pliers to hold the nuts inside the fuselage as you tighten the screws that retain the landing gear.
  • Page 7 Attach the cover plate over the landing gear screws using epoxy glue or silicone adhesive. Slide the fairings into place and attach with screws as shown. Elevator servo arm slot On each stab/elevator half, you will need to locate and open the slot for the servo arm as shown. The wood is pre-cut, but you will need to remove the covering over the slot as shown.
  • Page 8 Control Horn Installation Your Edge features phenolic control horns. The slots for the horns are pre-cut into all of the control surfaces. You will need to remove the covering over each of these locations. The best way to trim covering on this aircraft is with a hot pencil-tip soldering iron. This method gives a clean cut and also seals the edges of the covering at the cut line.
  • Page 9 5. Remove the horn and use the soldering iron to trim the covering just inside the square mark you made with the pencil. 7. Apply 30-minute epoxy liberally to the bottom of the horn and to the wood of the control surface. Install the horn.
  • Page 10 The rudder pull-pull control horn is installed in a similar fashion, except that it is double-sided. Remove the covering on both sides of the rudder over the slots as you did for the elevators and ailerons, apply epoxy to the center of the two horn pieces, and install into the rudder. Use alcohol to clean any excess epoxy and temporarily insert two 3mm bolts through the holes in the horn to ensure alignment while the glue cures.
  • Page 11 Pull-Pull cables The pull-pull cables for the rudder are assembled as shown in the following diagram: Install the rudder servo into the fuselage. Assemble the cable ends onto the servo arm as shown. Make sure the cables cross once inside the fuselage to form an "X", and assemble the cable ends at the rear onto the rudder horn.
  • Page 12 Adjust the lengths of the pull-pull cable to get good tension (just snug, with no sag, and no play in the rudder – “banjo-string” tight pull-pull wires will not make your plane fly better, but they will wear out your servo).
  • Page 13 Engine Mounting The Edge can use a variety of 50-70CC single cylinder engines. This manual shows the installation of a DA-60. Other engines are similar. Templates are included to locate the mounting holes for the DA-60, DA-50, and DLE-55. Tape the pattern in-place on the firewall as shown, aligning the lines on the template to match the firewall. Drill the engine mounting holes and remove the template.
  • Page 14 We have provided more than enough fasteners to secure the firewall to the engine box, if one of your engine-mounting bolts interferes with one of the firewall attaching screws, remove the firewall attaching screw if necessary – the engine-mounting bolt will take over its job, provided that your washer overlaps the aluminum angle-iron bracket.
  • Page 15 Mount the fuel tank with either large zip-ties or velcro straps to the wood tray in the fuselage as shown. It is recommended to place a foam rubber pad in-between the tank and the tray to dampen vibration. The fuel-feed line runs from the tank, to either a Du-Bro gasoline filler valve or a Y-connector and fuel dot, and then to the carburetor.

  • Page 16: Cowl Installation

    Cowl Installation The Edge cowl must be cut to allow clearance for the cylinder, spark plug, and muffler (if canister is not used) of the engine. We recommend the use of a dremel rotary tool for this step. Use eye protection and work in a well-ventilated area.
  • Page 18 Removing covering over access points Using your soldering iron or hobby knife, remove the covering over all of the required access points in the fuselage for the wing spar tube, aileron servo wires, anti-rotation pins, stab spar tube, exhaust venting plates, etc.
  • Page 19 Elevator Servos and Horizontal Stabs Mount your elevator servos inside the horizontal stabilizers as shown. Center the servos, and slide your servo arms onto the servo output splines. Rotate the servos and arms as necessary to access all fasteners to lock the arms in-place. Use threadlocker if indicated by the servo- arm manufacturer.
  • Page 21 The Edge includes a fiberglass tube installed into the fuselage to assist in cleanly routing your elevator servo extensions into the rear of the fuselage. A pull-string is pre-installed to help pull your servo extensions through the fiberglass tube. Install the horizontal stabilizers onto the fuselage using the carbon-fiber tube spar. The horizontal stabs are retained by two screws on each side, as shown.
  • Page 22 Aileron Servos Remove the covering over the servo openings in the bottom of the wings. Attach an 12-18” extension to the aileron servo and secure the extension as before. A pull-string is provided to help guide the extension through the wing. Install the servo with the servo head toward the front of the airplane, and attach the pushrod as you did for the elevator.
  • Page 23 Wing Attachment The wing attaches to the fuselage with one nylon thumb-screw per side. Your carbon-fiber wing tube is a snug fit into the wings and fuselage. This provides additional strength and fatigue resistance. As a result, you may need to periodically lubricate your wing tube. We recommend silicone spray-lube for this job.
  • Page 24 Wingtips Your Edge includes several optional parts to allow you to install the wingtip setup you desire. Your kit includes spacers, SFG's, and fiberglass racing tips. You can fly your Edge without any accessories installed on the wingtips, but you may wish to use some or all of these parts. The SFG's are vertical wings for your wingtips.
  • Page 25 Electric power The Edge flies very well as an electric aircraft. We recommend: Motor: Hacker Q80-8M ESC: Castle ICE2 HV160 Prop: Falcon Gas Carbon or wood 24x9, 24x10, 25x8.5W The pictured motor standoffs are 91mm long, and please note the depron cooling ducts, necessary to keep the motor cool during flight.
  • Page 26 Setup Information Center of Gravity - Measure at WINGTIP. 5.5 inches (140mm) back from leading edge is preferred. Allowable range is 5.0” to 5.5” (125-140mm) Control Setup: Throws High Rate Ailerons – 45 degrees Elevator – 50-55 degrees Rudder – Maximum throw available without interference High rate controls typically use 50-75% exponential Throws Mid Rate (if used) Ailerons - 30 degrees...