AeroWorks 100cc Edge 540 ARF-QB Assembly Manual
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AeroWorks 100cc Edge 540 ARF-QB Assembly Manual

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100cc Edge 540 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS
4903 Nome St– Denver, CO. 80239
www.aero-works.net
1

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Summary of Contents for AeroWorks 100cc Edge 540 ARF-QB

  • Page 1 100cc Edge 540 ARF-QB (Quick Build) ASSEMBLY MANUAL AEROWORKS 4903 Nome St– Denver, CO. 80239 www.aero-works.net...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Page Aeroworks Contact Information …………………………………………………………………………. 3 Introduction / Warranty…………………………………………………………………………. ………. 4 Kit Contents………………………………………………………………………………………………… 5 Items Needed To Complete ……………………………………………………………………………….. 8 Tightening and Re-shrinking The Covering ……………………………………………………………… 9 Ultracote™ Colors …………………………………………………………………………………………. 10 Checking Seams and Color Overlaps for Good Seal / Sealing Hinge Gaps ………..………………….. 11 Checking Hinges For Proper Throw……………………………………………………………………….

  • Page 3: Aeroworks Contact Information

    Further, Aeroworks reserves the right to change or modify this limited warranty without notice. In that Aeroworks has no control over the final assembly or materials used for final as- sembly, No liability shall be assumed nor accepted for any damage resulting from the use by the user of the final user-assembled product.

  • Page 4: Introduction / Warranty

    INTRODUCTION Your new 100cc Edge 540 ARF-QB is a highly aerobatic airplane. It is capable of both pre- cision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state of the art CAD design, LASER cut technology, and high quality included hardware. We hope you enjoy building and flying your 100cc Edge 540 ARF-QB.

  • Page 5: Kit Contents

    KIT CONTENTS 40x16mm hex style bolts 100cc Edge 540 ARF-QB (4) #6 bonded washers for the mounting of the canopy (4) 3mm split lock washers for the mounting of the canopy BASIC AIRCRAFT PARTS: 3.5(o.d.) x1000mm Antenna tube installed (2) 3.5(o.d.) x100mm pull-pull exit tube installed Fuselage with pre-installed vertical fin –...
  • Page 6 Horizontal Stabilizer with elevator assembly with (12) (4) #6 bonded washer for stab mounting pin point hinges (glued)---covered (4) 3mm split ring lock washers for stab mounting Elevators Pre-drilled for the mounting of the con- (4) 1.8mm cotter pins trol horns Rudder with (7) pin point hinges (not glued) –...
  • Page 7 (1)6x100x160mm Foam for the Fuel Tank (8) 8x450mm Nylon Ties for the fuel tank mounting (10) 3x150mm Small Nylon Ties for the fuel line (6) 356x12.5mm Velcro (1) Card Stock (8”x11”) for making the template for cutting of cowling (1) pre cut template for cutting the bottom of the cowl (1) Paper Degree Meter for the Rudder (1) Φ12mm Aluminum Insert (6) Rubber Grommets –...

  • Page 8: Items Needed To Complete

    ITEMS NEEDED TO COMPLETE Hardware: • Allen wrenches US and Metric. • Dremel cutting disc and sanding drum tool • Electric drill and selection of bits • Flat head screwdriver • Hobby heat gun • Hobby iron with protective sock •...

  • Page 9: Tightening And Re-Shrinking The Covering

    TIGHTENING AND RE-SHRINKING THE COVERING 1. Open your kit slowly and take care not to dam- 3. If bubbles persist, use a small pin to punch holes age any parts of the kit. Remove all parts from in the bubble to relieve trapped air and reheat. their plastic protective covers for inspection.

  • Page 10: Ultracote™ Colors

    Ultracote™ Colors 1. Your model is covered with Ultracote™ cover- ing. In case of repairs, the colors are: Yellow/Charcoal/White Scheme Cub Yellow #884 Pearl Charcoal #846 White #870 Orange/Charcoal/White Scheme Orange #877 Pearl Charcoal #846 White #870...

  • Page 11: Checking Seams And Color Overlaps For Good Seal Sealing Hinge Gaps

    It is the responsibility of the purchaser / operator to check the covering seams and overlaps for security and a good seal. Aeroworks is not responsible for failure of covering seams or overlaps during flight. Note: If covering continues to lift apply a small amount of thin CA underneath the covering.

  • Page 12: Checking Hinges For Proper Throw

    CHECKING HINGES FOR PROPER THROW If the elevator hinges are tight follow the IMPORTANT same process as described for the wings. If control surfaces will not throw to full deflec- tion it may be necessary using a heat gun to Note: Once these steps have been completed apply heat to the knuckle of each hinge.

  • Page 13: Wing Assembly

    Y harness. 3. Attach the 6” extension to the servo lead and secure with Aeroworks Safety Clip. Ensure the connectors will not come apart from vibration or light tension.
  • Page 14 6. Attach the Y harness to the inboard servo lead 4. Remove the balsa stick with the pull string from and secure with an Aeroworks safety clip. En- the servo well and tie the pull string to the servo sure the connectors will not come apart from lead as shown.
  • Page 15 Pull Y harness through root end of wing. Builders Tip 10. Taping servo lead to the inside of the wing panel will help to prevent lead from dropping back inside of wing panel during transportation. Plug the male ends of the 24”extension into Install servo in servo well with the output shaft the female ends of the Y harness.
  • Page 16 Aileron Control Linkage Installation 1. Gather the aileron control linkage parts as shown below. There are (2) 4-40 pushrods, (4) 4-40 ball Install servo with servo mounting screws. link assemblies, (2) Flat washers (2) brass spacers, (2) left and (2) right side control horns, (1) Adjust- ment wrench (4) carbon reinforcement sleeves and (12) wood screws for each wing panel.
  • Page 17 3. Correct installation of ball link, flat washer and 5. Use thick CA on each screw prior to brass spacer to servo arm shown below. installing to lock screws in place Note: CA glues have a fast drying time. Remember to work quickly Note: Flat washer prevents ball link from coming off brass ball.
  • Page 18 Install servo arm to pushrod as shown below. Finished wing panel shown below, repeat steps for remaining wing panel. Plug the servos into the receiver and turn on. Ensure servos are centered and the servo arms are parallel to the aileron hinge line. Adjust the length of the pushrods so that the aileron is at the neutral position when the servo arms are parallel to the aileron hinge line.

  • Page 19: Stab And Elevator Assembly

    STAB AND ELEVATOR ASSEMBLY 4. Install servo with servo mounting screws. Elevator Servo Installation 1. The elevators have been pre-hinged and glued to the stabs and are ready for flight. No other steps are necessary for hinging. Clear covering has been provided for sealing of the hinge gaps if desired.
  • Page 20 2. Assemble the pushrod and control horn assem- 4. Align the control horns over the factory drilled bly as shown. The ball link goes between the holes. left and right sides of the control horn sides and is secured with a nylon lock nut. Note: Control horns have been set at a slight offset to allow for maximum torque at full deflection...
  • Page 21 7. Plug the 48” Extension into the female end of the servo. Secure the servo connectors with an Aeroworks Safety Clip Ensure the connectors will not come apart from vibration or light ten- sion.

  • Page 22: Rudder And Rudder Servos Installation

    RUDDER AND RUDDER SERVOS INSTALLATION Mix epoxy in mixing cup and use a tapered Rudder Installation stick to apply the epoxy inside the pre-drilled holes in the trailing edge of the fin. Apply Gather the rudder, hinges, epoxy, Vaseline, epoxy to one side of each hinge and insert the stir sticks, mixing cup and alcohol as shown.
  • Page 23 Mix epoxy in mixing cup and use a tapered Ensure there is minimal to no gap between fin stick to apply the epoxy inside the pre-drilled and rudder. Allow epoxy to fully cure. holes in the leading edge of the rudder. Apply epoxy onto each hinge.
  • Page 24 2. Assemble the ball links between the control 4. Use thick CA on each screw prior to installing to horns as shown. Secure with nylon lock nut. lock screws in place Note: Mount ball link to bottom control horn hole Note: CA glues have a fast drying time.
  • Page 25 8. Attach the Y harness to forward rudder servo (2) 3” to 3 1/2” Double out put servo arms, (2) lead and secure with an Aeroworks Safety Clip. Servo coupler assemblies supplied, (2) AW Ensure the connectors will not come apart from Safety Clips, all mounting hardware, and a 11”...
  • Page 26 11. Install rudder servos with servo mounting 13. Tie off or tape rudder cables to keep them from screws. pulling into fuse. 12. Feed the rudder cable through the pre installed 14. Pull the rudder cables from the fuse tail to the cable exit tube in the tail of the fuse toward the rudder servo tray.
  • Page 27 15. Install the ball link onto the threaded coupler as 17. Thread cable back through the brass swage tube shown below. as shown. 16. Thread the brass swag tube onto the pull pull 18. Loop the cable back through the brass swage cable followed by the threaded coupler.
  • Page 28 19. Crimp the brass tube with a crimping tool or pli- 21. A drop of thin CA may be applied to the swage ers. tube to help secure the cable. Rudder Servo Linkage Installation 20. Cut off excess cable as shown. 1.
  • Page 29 2. Install the rudder servo couplers onto the rear 4. Plug the rudder servo Y harness into the rudder servo arm as shown below. Install the cable ball channel of the receiver and power up. Turn on links on bottom of the servo arm. transmitter to center rudder servos.
  • Page 30 6. Attach the ball link to the rudder control horn as 8. Finished rudder linkage assembly shown below. shown below. 7. Using the included adjustment wrench, adjust 9. Adjust the tension of the pull pull cables until the pushrod length to prevent the servo from they are tight.

  • Page 31: Tail Wheel Installation

    3. Place tail wheel steering tiller over the pre- Tail Wheel Installation drilled holes in the bottom of the rudder. 1. Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown.
  • Page 32 5. Place tail wheel strut over the pre-drilled holes 7. Mount the tail wheel strut using three wood in the bottom rear of the fuse. screws. 6. Place a drop of thick CA on tail wheel strut 8. Attach the steering spring to one side of the rud- mounting screws before inserting in the pre- der tiller.
  • Page 33 9. Use pliers to twist spring ends closed around the rudder and tail wheel tillers. 10. Repeat for opposite side tail wheel spring. Ad- just length and spring tension so that tail wheel is centered when rudder is centered. 11. Tail wheel assembly is complete.

  • Page 34: Main Landing Gear And Wheel Pant Installation

    MAIN LANDING GEAR AND WHEEL PANT INSTALLATION 3. Align mounting holes in gear with pre installed Main Landing Gear Installation blind nuts in mounting plate of fuse. 1. Gather the landing gear parts as shown below. Note: Bolts have been offset to ensure correct in- (1) landing gear strut, (2) wheels, (2) axle as- stallation of gear.
  • Page 35 5. Bolt landing gear strut to fuse with (4) 8-32 bolts 7. Install the axle into the gear strut with nylon and washers. Ensure tapered edge of the gear lock nut. Only snug tighten at this time. strut is facing toward the rear. 6.
  • Page 36 11. Install the wheel and outer wheel collar. Use 9. Tighten the lock nut against the landing gear blue Loctite on the wheel collar set screw before strut to secure axel. final tightening. 12. Secure the wheel pant using the supplied 4-40 10.
  • Page 37 13. Final gear assembly with gear cover installed shown below.

  • Page 38: Engine Installation

    ENGINE INSTALLATION 3. Locate the laser cut engine mounting template Engine Installation for the DA-100. 1. The 100cc Edge 540 will accept a wide range of Note: If other engines are used the templates may engine types. Illustrations for a DA-100 be modified to fit you engine selection.
  • Page 39 5. Use a 1/4 drill bit to drill the engine mounting 7. Use a 1/4 drill bit to drill the ignition pickup holes in firewall. After drilling is finished, re- hole in the firewall. move template from firewall. 6. Mark a location for the ignition pickup to pass 8.

  • Page 40: Throttle And Choke Servo Installation

    9. Insert the (4) bolts through the engine mount and 11. Engine installation is now complete. install the engine standoffs and fender washers. Required distance from front of firewall to prop hub is 6 7/8”. Use correct amount of spacers and washers to achieve this distance.
  • Page 41 2. Attach the throttle pushrod to the engine throttle 4. Use a rotary cutting tool to cut out the throttle arm as shown. Ensure the servo and pushrod do servo mounting hole. not interfere with the standard muffler cans. Note: Cover engine with a towel or cloth or use masking tape to protect from any debris getting into the carburetor or cylinders.
  • Page 42 7. Assemble ball link to threaded coupler as shown 9. Cut the throttle pushrod to the proper length. below. 8. With the servo arm centered and the throttle arm 10. Gather the soldering tools as shown below. of the carburetor at half throttle, measure and mark the end of the throttle pushrod wire that Note: For best results we recommend a high will be inserted into the threaded coupler as...
  • Page 43 11. Solder the threaded coupler to the throttle 13. Attach the throttle pushrod with the 4/40 ball pushrod wire. links and secure. Power up the receiver and throttle servo and adjust pushrod for proper op- Note: Lightly sand end of rod for best bond. eration.
  • Page 44 3. Use a rubber grommet (supplied) to protect the Manual Choke Installation cowl from the manual choke pushrod. 1. Assemble the rod as shown below. Follow the previous steps on pushrod installation. 2. Manual choke installation shown below.

  • Page 45: Ignition Installation

    IGNITION INSTALLATION Ignition module Installation 3. Position the ignition module inside the engine box to allow both of the spark plug leads to exit 1. Gather the supplied mounting hardware to be and properly connect to the engine without ex- used.
  • Page 46 6. Install the ignition module and the foam pad 8. Thread ignition connector through firewall and with a nylon tie as shown. connect ignition timing connectors with an Aeroworks Safety Clip. Ensure the connectors will not come apart from vibration or light ten- sion.
  • Page 47 9. Install the ignition switch as shown below. Fal- low the switch manufacturers directions for spe- cific switch mounting instructions. Note: Ensure switch does not interfere with mount- ing of wings.

  • Page 48: Fuel Tank Assembly And Installation

    FUEL TANK ASSEMBLY AND INSTALLATION 3. Assemble the fuel pick up line, rubber stopper Fuel Tank Assembly and metal end caps. As shown below. 1. Gather the fuel tank parts as shown below. A 1000cc (34oz) fuel tank has been provided. 2.
  • Page 49 5. Final assembly of rubber fuel stopper with fuel 7. Install the fuel tubing and clunk. Secure the fuel pick up tube shown below. tubing with nylon ties to the pick-up tube and clunk. 6. Install air vent tube into rubber stopper and bend 8.

  • Page 50: Fuel Tank Installation

    “T”, fuel filler dot, fuel filter and nylon ties. Note: It is recommended you always use a fuel filter in the fuel line to the carburetor. Note: The fuel “T” and fuel filter are not supplied, but are available through Aeroworks.
  • Page 51 4. Use nylon ties to secure fuel line. 6. Install foam rubber pad for fuel tank to rest on. Foam rubber will help prevent fuel from foam- Note: Gasoline will cause the fuel line to swell ing or getting air bubbles from engine vibration. over time.
  • Page 52 8. Mark and drill the fuel line exit hole in the bot- 10. Gather the supplied fuel filler dot and drill bits tom of the engine box. as shown below. Note: We have supplied rubber grommets for you Note: We recommend you start with a smaller size to route the fuel line through to give a drill bit then increase the bit size to the finished professional look.
  • Page 53 12. Starting with a smaller drill bit drill the fuel 14. Slide fuel filler line through the fuel dot and in- filler hole in the side of the fuse. Increase the stall the stopper on the end as shown below. size of the drill bit until the correct size is achieved.
  • Page 54 13. Route the vent line through F1 as shown below. Note: We have supplied rubber grommets for you to route the fuel line through to give a finished professional look. 14. Route the vent line out of the cowl as shown below.

  • Page 55: Standard Muffler/Cowl Installation

    STANDARD MUFFLER/COWL INSTALATION 3. Leave the canister tunnel cover off while flying. Standard Muffler Installation This will help provide better cooling for the en- gine. 1. Gather the standard muffler parts as shown: 2. Remove the canister tunnel cover as shown be- 4.
  • Page 56 5. Tape the provided card stock to the bottom of 7. Use the bottom mounting bolts to keep the tem- the fuse as shown below. plate secure. This will provide a consistent point of reference when marking and cutting the cowl. 6.
  • Page 57 9. Using a template enlarge the muffler exit hole 11. Cut out the holes on the paper template and rein- 1/4”. stall on the plane. Test fit the template, make any changes that may be needed at this time. 12. Re attach template to cowl and mark cut loca- tions for exhaust stack exit holes.
  • Page 58 Always check the operating temperature of your engine to prevent any damage from occurring. Aeroworks is not responsible for damages incurred from improper engine cooling. 16. Use a hobby knife to remove the covering around the hot air exit holes.

  • Page 59: Canister Muffler/Cowl Installation

    CANISTER/COWL INSTALLATION 2. Use a hobby knife to remove the covering Canister Installation around the hot air exit holes. Gather the canister muffler parts as shown: Shown: MTW TD75K Canister (Front Exit) 70mm Drop flex headers Teflon Couplers Mounting Clamps Using a covering iron seal the covering around 3.
  • Page 60 Remove the (4) Phillips head screws holding the 6. Test fit canister mount in the fuse. If necessary canister hatch in place. sand canister mount to achieve proper fit. 5. Canister mounting bracket position shown be- 7. Use 30 Minute epoxy to secure the canister low.
  • Page 61 8. Reinstall the canister mount in the fuse. Allow 10. Assemble the canisters to the headers with the epoxy to fully cure before moving on to the next Teflon coupler and clamps in accordance with step. manufactures instructions. 11. Slide the canisters into the canister tunnel as Canister mount should be positioned as shown shown below.
  • Page 62 12. Secure the headers in place using the mounting 14. Mark air exit slots on bottom using the supplied bolts provided with your engine. Use blue Loc- template as shown. tite to secure the bolts. 13. Finished canister installation shown below. 15.

  • Page 63: Radio Installation

    RADIO INSTALLATION 1. Gather the receiver, battery, switch, regulator 3. Use (2) of the supplied Velcro straps to secure and mounting hardware as shown below. the receiver battery in place. Install the Velcro straps as shown below. 2. Install the receiver regulator following the 4.
  • Page 64 7. Apply baby powder or corn starch to antenna 5. Final battery installation shown below. wires to assist getting antennas into their guide tubes. 6. Install the receiver following the same method as 8. Push receiver antennas all the way into the pre the receiver battery.
  • Page 65 9. Tape the receiver antenna wires to the end of the antenna guide tubes and to the radio floor as shown. This will prevent the antenna wire from vibrating back out. 10. Install the receiver switch as shown below. Make sure that the placement of the switch will not in- terfere with the wing.

  • Page 66: Preflight Preparation

    PRE-FLIGHT PREPARATION 1. Gather the (4) 8-32 wing mounting bolts, (4) #8 3. Gather the (4) 4-40 stab mounting bolts and large rubber backed washers and (4) hair pins. (4) #6 small rubber backed washers. Note: Always check wing attachment bolts are securely tightened.
  • Page 67 5. Gather the (2) 4-40 and (2) 6-32 cowl mounting 7. Secure bottom section of cowl with bolts and (4) #6 small rubber backed washers. 4-40 x 16mm button head bolts and #6 bonded Mount the cowl using the cowl mounting bolts washers.

  • Page 68: Decal Installation

    DECAL INSTALLATION Optional Decal Package Available 3. Placement of optional decal package shown, in- 1. Decals supplied with the kit may vary from the cluded decals will differ. photos below. Decal application steps will be similar. Gather supplied decals, transfer tape, ruler, scis- sors, hobby knife, plastic squeegee or credit card, Windex or Application fluid like Rapid Tac.
  • Page 69 6. Remove backing from Clear transfer tape. 4. Placement of optional decal package shown, in- cluded decals will differ. 5. Cut transfer tape to accommodate decal size. 7. Apply clear transfer tape over top of decal. Note: Transfer tape will be reused. DO NOT throw away any transfer tape until decal placement is complete.
  • Page 70 8. Press transfer tape to top of decal. 10. Spray model surface with application fluid, Windex or soapy water solution. 9. Peel backing from decal. 11. Spray back side of decal with application fluid, Windex or soapy water solution.
  • Page 71 12. Position decal in proper location. Application 14. Pull transfer tape from top of decal. Take care fluid will allow decal to be moved slightly. not to pull away or damage decal. 13. Using a plastic squeegee or credit card. Spread de- 15.

  • Page 72: Center Of Gravity- Cg Buddy

    Center Of Gravity– CG Buddy 1. Aeroworks has included the new CG Buddy 4. Slide wing back against the fuse as shown be- with the 100cc Edge 540. This handy tool will low. allow the builder to balance the airplane without the need for an assistant.
  • Page 73 8. Lift airplane from center handle as shown, plane should sit level when lifted. Balance the Edge 540 without fuel in the tank with the batteries installed and READY TO FLY. Try to balance the model by moving the batteries and receiver before adding any ballast.

  • Page 74: Center Of Gravity / Control Throws

    CENTER OF GRAVITY - CONTROL THROWS Start at recommended CG until you are com- Center of Gravity fortable with the flight characteristics of the Warning, DO NOT skip this step! aircraft. You may find this a bit nose heavy at first but that is fine to start with.
  • Page 75 2. Elevator throw measured in inches at the widest 4. Elevator throw measured in degrees. Locate point of the elevator throw meter at widest point of the elevator. 3. Use the supplied flight control deflection meter . It is recom- to measure the throws in degrees 5.
  • Page 76 6. Gather the Rudder Throw Meter (Supplied) 8. Secure the tabs to the fin using scotch tape. As and scotch tape. shown below. Degrees are measured at the tip of the boost 7. Slide the throw meter under the rudder boost tab. tab as shown below.

  • Page 77: Control Throw Deflection Table

    Control Throw Deflection Table Low Rate High Rate Aileron 2” or 20˚ up 3 1/4” or 30˚ up 2” or 20˚ down 3 1/4” or 30˚ down Rudder N/A” or 25˚ left N/A” or 35˚ left N/A” or 25˚ right N/A”...

  • Page 78: Preflight Check List

    Preflight Check List Range check: Do a range check with and without Center of Gravity: Check CG is set properly. the engine running in accordance with the radio manufacturer instructions. If there is insuffi- Engine: The engine should run smoothly at all cient range or a large reduction with the engine throttle settings with smooth transition from running, do not fly until it is resolved!
  • Page 79 Spins upright and inverted • Flat Spins upright and inverted • Harriers upright and inverted • Water falls • Torque Rolls • Rolling circles • Rolling harrier The sky and your imagination are you only limits. FLY and ENJOY! AEROWORKS World Class Aircraft...
  • Page 80 Edge 540 CUSTOMER NOTES ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ___________________________________________________________________________ __________________________________________________________________________...

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