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Extreme Flight 3DHobbyShop Edge 540 Assembly Manual

Airframe – 48” arf rc aircraft
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Assembly Manual / Airframe – 48" 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.
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Summary of Contents for Extreme Flight 3DHobbyShop Edge 540

  • Page 1 Assembly Manual / Airframe – 48” 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 ASSEMBLY Remove covering material over landing gear slot as indicated with a sharp hobby knife. Remove covering from bottom of fuselage in the area shown to function as a hot-air vent.
  • Page 5 Trial-fit the wire landing gear into the fuselage slot. Make sure you can easily put it all the way into the slot. Apply a generous amount of 30-minute epoxy into the slot and install the landing gear. Apply more epoxy into the slot and install the gear brace plywood piece as shown. Slide it all the way into the slot.
  • Page 6 Clean up any excess epoxy using rubbing alcohol on a paper towel. All the landing gear to cure. Remove the covering on both sides of the fuselage as shown, for the wing spar tube, aileron wire access, wing retaining screw, and anti-rotation pin. Use a sharp hobby knife.
  • Page 7 Make sure your hobby knife blade is very sharp, and remove the covering over the horizontal stabilizer opening in each side of the fuselage as shown.
  • Page 8 Slide the wheel pant over the end of the landing gear as shown. Slide on first wheel collar as shown. Slide on wheel and second wheel collar, center wheel in wheel pant and tighten collars with 1.5mm hex wrench.
  • Page 9 Use two of the included wood screws to install the nylon plastic gear strap onto the wheel pant as shown. Apply some 30 minute epoxy between the strap and the pant before tightening the screws. Take your time with this step, make sure the wood screws are penetrating into the plywood piece inside the pant.
  • Page 10 Locate the gear leg fairing. Remove the covering over the groove in the fairing as shown. Apply a generous amount of 30 minute epoxy into the groove and install the fairing as shown. Allow all epoxy to cure.
  • Page 11 Remove covering over control horn slot in rudder as shown. Install rudder horn into slot with CA glue as shown.
  • Page 12 Remove covering over tail wheel wire slot in bottom of rudder as shown and test-fit tailwheel wire. When satisfied with fit, apply 30-minute epoxy into slot, install wire, and allow to cure. Install rudder onto fuselage, align with fuselage, and when satisfied with alignment, apply 2 drops of thin CA onto each hinge as shown.
  • Page 13 Install tailwheel bracket using ONE wood screw as shown. Bracket should be able to swing left and right. Install tailwheel and tailwheel collar, tightening set screw in collar with 1.5mm hex wrench. Make sure rudder swings easily left and right. Apply a piece of masking tape as shown to hold rudder straight and centered.
  • Page 14 Install rudder servo as shown, in the orientation shown inside fuselage. Servo connectors are installed onto servo arms as shown. Drill the holes in your servo arms to the right size to allow the connectors to easily spin on the servo arm. Attach with the nut, but do not tighten all the way, the connector must remain able to twist on the servo arm.
  • Page 15 Please examine the rudder pull-pull system assembly diagram closely: Start by attaching the cables to the pull-wire end at the front, where they will attach to the . Crimp well, preferably by making creases in the crimp tube with a sharp pliers or cutters, rather than smashing it completely flat.
  • Page 16 Assemble the rear ends of the rudder pull cables onto the rudder as shown. Use thick CA to lock the nut on the bottom of the rudder horn. Make sure there is not much slack in the cable, look inside the fuselage to make sure the cables have no kinks in them and are routed correctly.
  • Page 17 Locate the carbon wing spar tube and insert it into the fuselage. The carbon tube is NOT to be glued in, it is to remain removable. Insert the horizontal stabilizer into the fuselage as shown. Measure from the tube to the stabilizer on both sides of the fuselage as shown to make sure the stabilizer is straight. Measure the stabilizer side-to-side to make sure it is centered.
  • Page 18 Install the elevator half with the joiner rod attached WITHOUT glue and make sure it can swing easily 45 degrees up and 45 degrees down. You will have a small gap in the hingeline. NOTE – Measuring 45 degrees is demonstrated later in this manual in the section on the elevator servo Apply two large drops of thin CA to the hinges to permanently install the elevator.
  • Page 19 Trial fit the other side elevator half, make sure the elevators are straight and level to each other. A slight misalignment of elevator halves will not affect flight performance, but you can make sure that your elevators will be perfectly aligned by taking a bit of time to align them now. Sand the slot in the elevator if necessary to align elevators.
  • Page 20 Install ESC onto the side of the motor box with zip ties as shown. The cowl is mounted onto the fuselage with 4 wood screws. These screws go into the small plywood squares on the front inside of the fuselage. Place small strips of tape over the squares as shown. Install the canopy hatch.
  • Page 21 Remove covering over the elevator servo opening as shown.
  • Page 22 Attach a 12” Extension onto the elevator servo and install the servo as shown. Assemble the longest pushrod in your kit with the ball link and control horn as shown. Use thick CA to lock the nut on the control horn. DO NOT GLUE INTO THE ELEVATOR YET. On 3D planes, it is very important to have 45 degrees of elevator throw on high-rates setting.
  • Page 23 If you don’t have enough throw, you can choose to either install a longer arm on your servo, or you can reduce the height of your elevator horn by trimming it as shown.
  • Page 24 This will allow you to insert the arm approx 1/8” farther into the elevator, increasing the throw. When you are ready, apply medium or thick CA glue generously to the elevator horn and insert it into the elevator. Assemble the ailerons onto the wings, flex them up and down to check for free motion, and drip thin CA glue onto each hinge.
  • Page 25 Install 6” extension onto aileron servo and use pull-string installed in wing to pull aileron servo wire through wing. Install servo as shown, and assemble pushrod/horn onto aileron horn. Install aileron control horn into slot with medium or thick CA glue and assemble aileron pushrod onto servo arm, exactly as you assembled the elevator control system.
  • Page 26 If desired, you can mount your receiver on the balsa receiver plate (marked Rx) and glue the plate into the bottom of the fuselage as shown. Plug your servos and ESC into your receiver, attach your battery and test your radio system. Check for correct motor running direction now, before your prop is installed.
  • Page 27 Control Throws and Exponential Low/Precision Rates (in degrees and inches) and Corresponding Exponential Aileron 15 degrees .75” 30% Expo Elevator 13 degrees 1.25” 30% Expo Rudder 45 degrees 3.5” 75% Expo High/3D Rates (in degrees and inches) and Corresponding Exponential Aileron 28 degrees 1.25”...
  • Page 28 We hope you enjoy your 3D HOBBY SHOP Aircraft. Be sure to look for new aircraft and products coming soon from 3 D H O B B Y S H O P . C O M Copyright 2014 3D Hobby Shop...