Flex innovations JASE THE ACE DUSSIA FPM2400A Instruction Manual

Edge 540 g2 edition 120cc

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Instruction Manual

ARF

120cc

G2 Edition

by Jase "THE ACE" Dussia

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Page 1 Instruction Manual 120cc G2 Edition by Jase “THE ACE” Dussia...
Page 2 BEFORE CONTINUING WITH THIS INSTRUCTION MANUAL OR THE ASSEMBLY OF YOUR AIRCRAFT, PLEASE VISIT OUR WEBSITE FOR THE LATEST PRODUCT UPDATES, FEATURE CHANGES AND MANUAL ADDENDUMS FOR THIS PRODUCT. www.flexinnovations.com/product/edge-540-120cc-g2-arf...
Page 3: Table Of Contents
TABLE OF CONTENTS Introduction ..........................1 Specifications: ................................. 2 Required Equipment: ..............................2 Optional Equipment: ..............................3 Ultracote®/Oracover® Colors: ............................. 4 Using this Manual ..........................5 Airframe Assembly ........................7 Rudder Control Horn Installation ....................7 Main Landing Gear Installation ..................... 9 Landing Gear Installation ............................
Page 4 Before First Flight .......................... 57 AMA Safety Code ........................... 58 Replacement Parts ......................... 59 Optional Accessories ........................60 Limited Warranty ........................61 Building and Flying Notes ....................63...
Page 5: Introduction
Edge 540 120cc G2 Instruction Manual INTRODUCTION Flown to 1st place by Jase “The Ace” Dussia at the Del Norte Fly Fest 2023, the Flex Innovations Edge 540 120cc proves to be a testament to excellence in aerobatic competition. The Edge 540 120cc not only captures the sleek aesthetics of its full-size counterpart but also boasts exceptional performance capabilities.
Page 6: Specifications
(2) 48-inch (1200 mm) FPZ1049 Rudder: Tail-Mounted Push-Pull – (1) 36-inch (920 mm) FPZA1048 Forward-Mounted Pull-Pull – None Required Throttle: (1) 9-inch (230cm) FPZA1044 Spinner: Spinner: 5-inch (127 mm) Flex Innovations 5-Inch Carbon Fiber, Ultimate Style Spinner (FPM2426A & FPM2426B recommended)
Page 7: Optional Equipment
Aura 8 Professional FPM1623 32oz Lightweight Fuel/Smoke Tank (for smoke) DP1000 Dualsky DP1000 Brushless Smoke Pump FPM1314 Flex Innovations Premium Wing and Tail Bag Set FPM2416A Edge 540 120cc G2 Pilot Figure Yellow FPM2416B Edge 540 120cc G2 Pilot Figure Green FPM1332 Protection Pack –...
Page 8: Ultracote®/Oracover® Colors
Edge 540 120cc G2 Instruction Manual Ultracote®/Oracover® Colors: GREEN Scheme: Ultracote® Oracover® Royal Green (only available through Flex FPM1316) Silver (HANU881) Silver (21-023) Black (HANU874) Black (21-071) White (HANU870) White (21-010) Yellow Scheme: Ultracote® Oracover® Cub Yellow (HAN884) Cub Yellow (21-030) True Red (HANU866) Ferrari Red (21-023) Light Gray (HANU882)
Page 9: Using This Manual
All instructions, warranties and other collateral documents are subject to change at the sole discretion of Flex Innovations, LLC. For up-to-date product literature, please visit our website at www.flexinnovations.com and navigate to the product page for this product.
Page 10 Edge 540 120cc G2 Instruction Manual 7. If you are not an experienced pilot, or have not flown a high-performance model before, it is recommended that you seek assistance from an experienced pilot in your R/C club for your first flights. If you're not a member of a club, the Academy of Model Aeronautics (AMA) has information about clubs in your area whose membership includes experienced pilots.
Page 11: Airframe Assembly
Edge 540 120cc G2 Instruction Manual AIRFRAME ASSEMBLY RUDDER CONTROL HORN INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Rudder Control Horns (set of 2) o Isopropyl Alcohol Hobby Knife with a o Rudder Control Horn Base (1) o 30-minute Epoxy #11 blade o Paper Towels...
Page 12 Edge 540 120cc G2 Instruction Manual ⃞ 3. Apply epoxy to the control horn slots and control horn and insert the control horn into its corresponding slots. Double check the rudder control horn to ensure it is straight and seated properly. Use a paper towel and isopropyl alcohol to clean up any excess epoxy. Set the rudder aside and let the epoxy fully cure.
Page 13: Main Landing Gear Installation
Edge 540 120cc G2 Instruction Manual MAIN LANDING GEAR INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o 1.5mm Hex Driver o Blue Thread Lock o Landing Gear o 2.5mm Hex Driver o Red Thread Lock o Wheel Pants (L &...
Page 14: Landing Gear Cuff Installation
Edge 540 120cc G2 Instruction Manual Landing Gear Cuff Installation The landing gear cuffs are glued to the landing gear itself, and not the fuselage. This allows for easy removal of the landing gear. ⃞ 1. Slide the gear cuff up into place against the fuselage. Apply a piece of masking tape at the bottom edge of the cuff on each side of the landing gear.
Page 15: Wheel, Axle, And Wheel Pant Installation
Edge 540 120cc G2 Instruction Manual ⃞ 3. Slide the gear cuff back up into place. Tape over the bottom of cuff to ensure no residual adhesive runs down the landing gear. Also tape the top of the cuff to the fuselage to keep it in place while the adhesive sets.
Page 16 Edge 540 120cc G2 Instruction Manual ⃞ 2. Put the wheel in place by sliding it over the axle. A collar will likely need to be installed to keep the wheel in place laterally. ⃞ 3. Locate the wheel pant saver and mount it be aligning the set screw with the flat spot on the axle.
Page 17 Edge 540 120cc G2 Instruction Manual ⃞ 6. Use blue thread lock, re-install and tighten the wheel pants for flight. Allow the adhesive to cure for at least 24...
Page 18: Rudder And Tailwheel Installation
Edge 540 120cc G2 Instruction Manual RUDDER AND TAILWHEEL INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage o 2.5mm Hex Driver o Blue Thread Lock o Rudder o Hobby knife o Rudder Hinge Wire o Tail Gear Assembly o Steering Ball Link (1) o M3X16mm Socket Head Cap Screws (3)
Page 19: Rudder Servo Opening
Edge 540 120cc G2 Instruction Manual Rudder Servo Opening ⃞ 1. Using a flashlight locate the opening for the rudder servo. ⃞ 2. Double check that you are exposing the servo opening that is on the same side as the rudder control horn.
Page 20 Edge 540 120cc G2 Instruction Manual ⃞ 4. Once the adhesive is cured, slide the wire steering arm through the ball link and bolt the tail wheel mount in place using the supplied bolts and blue thread lock. ⃞ 5. You can trim the steering wire leaving some overhang.
Page 21: Aileron Servo And Linkage Installation
Edge 540 120cc G2 Instruction Manual AILERON SERVO AND LINKAGE INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Main Wing Panels (2) o 2.5mm Hex Driver o Thin CA o Aileron Linkage (4) o 5.5mm Nut Driver o Blue Thread Lock o Aileron Servos (4) o #1 Phillips o Heat shrink, dental floss or...
Page 22 Edge 540 120cc G2 Instruction Manual servo arm. The order of hardware components, starting from the top of the servo is as follows: o M3x20 socket head cap screw o M3 washer o Ball Linkage o Conical Spacer (narrow, pointed side towards the ball link) o Servo Arm o M3 washer o M3 locknut...
Page 23 Edge 540 120cc G2 Instruction Manual Note: The angle of the linkage when centered is correct. As the servo arm rotates and the control surface deflects, the linkage will straighten. ⃞ 10. Once the root aileron servo is connected, set your end points in both directions so that the ailerons travel 38 degrees up and 37 degrees down, at the root of the aileron, when set to high rates.
Page 24 Edge 540 120cc G2 Instruction Manual ⃞ 12. Be sure the leads of the connector are secured within the wing to help prevent them from coming unplugged.
Page 25: Elevator Servo And Linkage Installation
Edge 540 120cc G2 Instruction Manual ELEVATOR SERVO AND LINKAGE INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Left and Right Horizontal o 2.5mm Hex o Thin CA o Blue Thread Lock Stabilizers (2) Driver o Elevator Servos (2) o 5.5mm Nut o Dental Floss, Heat Shrink or o Elevator Servo Arm 2”...
Page 26 Edge 540 120cc G2 Instruction Manual to have access to each clamping screw. Use sub-trim to set the servo arm perfectly perpendicular before installing the elevator. ⃞ 5. Using an elevator pushrod, assemble the elevator linkages and ball links so that the total length from center of ball to center of ball is approximately 3 ¼...
Page 27 Edge 540 120cc G2 Instruction Manual Quique Pro Tip: • For elevator centering, it is best to install the stabilizers onto the fuselage and stand approximately 10 feet (3m) behind the aircraft while sighting the two elevator halves. Using this method, you can best align the most important part of the control surface, the wider section, rather than referencing something less important, like the elevator counterbalance.
Page 28: Rudder Servo And Linkage Installation
Edge 540 120cc G2 Instruction Manual RUDDER SERVO AND LINKAGE INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o 2.5mm Hex Driver o Thin CA o Rudder Servo o 5.5mm Nut Driver o Blue Thread Lock o Rudder Servo Arm 2”...
Page 29 Edge 540 120cc G2 Instruction Manual o M3x20 socket head cap screw o M3 washer o Ball Linkage o Servo Arm o M3 washer o M3 locknut Note: There is a conical spacer supplied with the elevator linkage hardware. If using the recommended servo and servo arm, this spacer is not needed.
Page 30: Gas Power Setup
Loop Tape o Fuell Filler o Cable Ties The Flex Innovations 32oz Lightweight Fuel Tank is included with your Edge 540 120cc G2. ⃞ 1. Assemble your fuel tank. Before installing the fuel tank check all fittings are properly installed and that the clunk line inside the tank is appropriately sized. Adjust as necessary.
Page 31 Edge 540 120cc G2 Instruction Manual ⃞ 2. As shown in the picture on the previous page, the fuel tank tray has plenty of room for your fuel tank. If you are using a single tank, you can place the fuel tank in the middle of the tray, If you plan on using a smoke system, two of the 32oz Lightweight Fuel/Smoke tanks (FPM1623) should be used, installed side by side.
Page 32 Edge 540 120cc G2 Instruction Manual ⃞ 5. The vent line shrould warp around the tank and should then exit the bottom of the fuselage. After the vent line exits the fuselage. A piece of metal tubing coming from the bottom of the airplane can be used for vent.
Page 33: Engine Installation
Edge 540 120cc G2 Instruction Manual ENGINE INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o Drill o Blue Thread Lock o ⅛-inch (3mm) Drill Bit o Engine o Thin CA o Engine Standoffs (15mm) o ¼-inch (6.5mm) Drill Bit o ¼-20 Blind Nut (4) o ¼-inch Hex Driver o ¼-20 x 1¾-inch Socket...
Page 34: 120 Throttle Servo And Linkage Installation
Edge 540 120cc G2 Instruction Manual DA-120 Throttle Servo and Linkage Installation Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o #1 Phillips Screwdriver o Thin CA o Throttle Servo o 2.5mm Hex Driver o Blue Thread Lock o 9-inch (230mm) Servo o Heat Shrink, Dental Floss or Extension...
Page 35 Edge 540 120cc G2 Instruction Manual ⃞ 2. Attach the 9-inch (600mm) servo extension to the throttle servo. Use a Servo Connector Safety Clip (FPZA1040), thread or heat shrink tubing to secure the extension in place. Mount the servo with the output shaft towards the motor and route the servo extension appropriately through the aircraft.
Page 36: Ignition Installation
Edge 540 120cc G2 Instruction Manual Jase’s Pro Tips: • Use the shortest servo arm possible while still getting full throttle arm movement on your engine. Your throttle end points should be around 110-120% when finished with the installation. A faster servo (like the Potenza DS49010HV) with a shorter arm is preferred over a slower servo with a longer arm.
Page 37 Edge 540 120cc G2 Instruction Manual a #11 blade to remove the covering from the hole of your choice. Test fit your switch and modify the hole if needed. Secure it in place using the screws included with your switch. If your switch mounting screws thread into metal, be sure to apply blue thread lock.
Page 38 Edge 540 120cc G2 Instruction Manual Ignition Battery ➞ Ignition Switch ➞ Ignition Regulator ➞ Ignition ➞ Engine Or (if using an IBEC): Receiver Channel ➞ IBEC ➞ Ignition ➞ Engine ⃞ 6. Thread a wood screw into each of the four access hatch screw holes in the motor box. Apply thin CA to each of the holes to harden the threads ⃞...
Page 39: Exhaust And Cowling Installation
Edge 540 120cc G2 Instruction Manual EXHAUST AND COWLING INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o Rotary Tool o Thin CA o Cowling o Rotary Tool Sanding o CA Accelerator o Cowling Baffles o Blue Thread Lock Drum o Your Exhaust Choice o Rotary Tool Cut-Off...
Page 40 Edge 540 120cc G2 Instruction Manual ⃞ 6A. Mark where the exhaust needs to be relieved through the template. ⃞ 7A. Cut the holes out of the template, and bolt to the cowling itself. Transfer your marking to the cowling ⃞...
Page 41: Canister Installation (B)
Edge 540 120cc G2 Instruction Manual Canister Installation (B) Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o 4mm Driver o Red Silicone (RTV) o 2-to-1 Exhaust Header o 2.5mm Hex Driver o Paper Towels o Canisters o #11 Exacto Knife o Exhaust Gaskets (2) o Canister Mount Plate...
Page 42: Engine Baffling And Cooling Installation
Edge 540 120cc G2 Instruction Manual ⃞ 3B. Re-insert your exhaust into the fuselage and slide your canister mount over the exhaust. Decide the location that best suits your mount. For the provided mount and the KS 3086 canister, the optimum location is against the rear of the F2 former, located just aft of the landing gear mounting brackets.
Page 43 Edge 540 120cc G2 Instruction Manual ⃞ 5. The Edge 540 includes fuselage plates installed on the bottom for can/tuned pipe use and air venting even with a stock muffler setup. ⃞ 6. To install these plates, remove the covering where the plate provisions are located. Each plate is installed using four wood screws.
Page 44: Cowling, Propeller And Spinner Final Installation
Edge 540 120cc G2 Instruction Manual COWLING, PROPELLER AND SPINNER FINAL INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o M3 Hex Driver o Blue Thread Lock o Cowling o M2 Hex Driver o Propeller (Spinner) o Spinner o (4)M4x20 Socket Head Hex Bolt o (4) M4 Washer...
Page 45: Radio Installation
Edge 540 120cc G2 Instruction Manual RADIO INSTALLATION Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o #1 Phillips Screwdriver o Receiver o Hobby Knife o Receiver Switch o Aura 8 or 12 Professional (Optional) o Receiver Batteries o Hook and Loop Straps o Adhesive-Backed Hook and Loop Tape...
Page 46 Edge 540 120cc G2 Instruction Manual Traditional switch Power safe location switch location ⃞ 3. Locate the RX/Aura switch just under the canopy. Note that there are switch locations on both sides of the fuselage for both traditional and power safe switches. Remove the covering from the hole of your choice using a hobby knife with a sharp blade and install your RX switch.
Page 47 Edge 540 120cc G2 Instruction Manual ⃞ 4. Make all the necessary servo connections. Depending on the center of gravity (see the CG section), install your (2) receiver batteries in one of three mounting locations provided in the Edge. They are located as follows: o Receiver &...
Page 48: Side Force Generators Assembly
Edge 540 120cc G2 Instruction Manual SIDE FORCE GENERATORS ASSEMBLY Required for this section Components Tools Adhesives/Building Materials o SFGs (2) o Thin CA o SFG Spacers (2) o CA accelerator (optional) ⃞ 1. Align an SFG spacer with the SFG and apply a small amount thin CA around the joint to hold the spacer in place to the SFG.
Page 49: Field Assembly
Edge 540 120cc G2 Instruction Manual FIELD ASSEMBLY Required for this section Components Tools Adhesives/Building Materials o Fuselage Assembly o Main Wings (2) o Anti-rotation Tube o WingTube o Stab Tube o Canopy Hatch ⃞ 1. Pull out the Flex Canopy Speed-Lock knob until it bottoms out, then twist it CW or CCW 1/4 turn.
Page 50 Edge 540 120cc G2 Instruction Manual ⃞ 2. Unlock the 4 wing Flex Speed-Locks from both right and left side. To unlock them you need to pull out on the knob and then slide it up until it reaches its limit. Note that the Flex Speed-Lock design has a plastic tube extension on the top that shows the unlock position when the tube is sticking out of the top of the airplane frame.
Page 51 Edge 540 120cc G2 Instruction Manual ⃞ 4. Proceed to lock the Flex Speed-Locks by pushing down on the plastic tubes until they are flush with the fuselage, and you hear a “click”. If the plastic tube is not flush with the top of the fuselage, then you know the Flex Speed-Lock is not properly locked.
Page 52 Edge 540 120cc G2 Instruction Manual ⃞ 6. Unlock the horizontal stabilizer Flex Speed-Locks from both right and left side. To unlock them you need to pull out on the knob and then slide it down until it reaches its limit. ⃞...
Page 53 Edge 540 120cc G2 Instruction Manual ⃞ 9. Install the canopy hatch back on the fuselage by inserting the two front pins in the fuselage and seat flush to the fuselage. One in place, then proceed to lock the canopy. Turn the Flex Canopy Speed-Lock knob ¼...
Page 54: Decal Installation
Edge 540 120cc G2 Instruction Manual DECAL INSTALLATION Use the drawings provided below for a guide to apply the decals to your model. ⃞ 1. Thoroughly clean the model to ensure it is free of oil, ﬁngerprints, and dust. ⃞ 2. Separate the decals, but do not remove the paper backing.
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Page 56 Edge 540 120cc G2 Instruction Manual Edge 540 120cc G2 Yellow Scheme...
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Page 59: Final Setup And Flying Notes
Setting the center of gravity (CG) is one of the most important steps for success, particularly with a new airplane. The Flex Innovations Edge 540 120cc G2 is a high-performance airplane with large control surface throws, and a very high thrust to weight ratio. These factors combined make the Edge a very enjoyable aircraft to ﬂy, but if the center of gravity is not within an acceptable range, it will...
Page 60: Aura 8 Professional
Edge 540 120cc G2 Instruction Manual Jase’s Pro Tip: o The measurement noted is the best CG location for flying the Edge 540 120cc G2, and where all tweaks to the airframe have been made. The aircraft is safe to fly within the range of 6- inches (153mm) to 6-23/32-inches (171mm) when measured from the leading edge of the wing but may not be flying at its optimized location.
Page 61: Range Testing
Edge 540 120cc G2 Instruction Manual RANGE TESTING Carefully follow the binding and range testing instructions included with your radio equipment. If there are any issues passing the test range, please consult your transmitter and receiver manuals or contact your transmitter and receiver manufacturer to determine the appropriate solution before attempting to fly.
Page 62: Ama Safety Code
Edge 540 120cc G2 Instruction Manual AMA SAFETY CODE When flying your aircraft, we recommend following the guidelines set by the Academy of Model Aeronautics (AMA). You can find their Safety handbook as well as more information on the AMA at their website, located at the address below.
Page 63: Replacement Parts
Edge 540 120cc G2 Instruction Manual REPLACEMENT PARTS FPM2400A Edge 540 120cc G2 ARF Yellow FPM2400B Edge 540 120cc G2 ARF Green FPM2401A Edge 540 120cc G2 Fuselage Yellow FPM2401B Edge 540 120cc G2 Fuselage Green FPM2402LA Edge 540 120cc G2 Left Wing with Horns Yellow FPM2402LB Edge 540 120cc G2 Left Wing with Horns Green FPM2402RA...
Page 64: Optional Accessories
Edge 540 120cc G2 Instruction Manual FPM2421 Edge 540 120cc G2 Flex Speed Locks CANOPY (1) FPM2422 Edge 540 120cc G2 Flex Speed Locks STAB (1) FPMA1035 Flex 120cc Wheel Pant Savers (2) FPM2424 Edge 540 120cc G2 Laser Cut Wood Parts FPM2425A Edge 540 120cc G2 Foam Cockpit Set Yellow FPM2425B...
Page 65: Limited Warranty
Edge 540 120cc G2 Instruction Manual LIMITED WARRANTY Warranty Coverage Flex Innovations LLC and its authorized resellers (“Flex”) warrant to the original purchaser that this product (the “Product”) will be free from defects in materials and workmanship at the date of purchase.
Page 66: Warranty Requirements
Edge 540 120cc G2 Instruction Manual These terms are governed by Florida law (without regard to conflict of law of principals). This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Page 67: Building And Flying Notes
Edge 540 120cc G2 Instruction Manual BUILDING AND FLYING NOTES...

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