AeroWorks 100cc Edge 540 ARF-QB Assembly Manual Download Page 62 | Manualshive

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62

12. Secure the headers in place using the mounting

bolts provided with your engine. Use blue Loc-
tite to secure the bolts.

13. Finished canister installation shown below.

14. Mark air exit slots on bottom using the supplied

template as shown.

15. Use a dremel to remove the air exit holes

marked in the previous step.

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Summary of Contents for 100cc Edge 540 ARF-QB

Page 1: ...1 100cc Edge 540 ARF QB Quick Build ASSEMBLY MANUAL AEROWORKS 4903 Nome St Denver CO 80239 www aero works net...

Page 2: ...tor Assembly 19 Rudder and Rudder Servos Installation 22 Tail Wheel Installation 31 Main Landing Gear and Wheel Pant Installation 34 Engine Installation 38 Throttle and Choke Servo Installation 40 Ign...

Page 3: ...ship at the date of purchase This limited warranty does not cover any component parts damaged by use or modification In no case shall Aeroworks liability exceed the original cost of the purchased kit...

Page 4: ...sembly of your new model Inventory and inspect all parts and hardware for any imperfec tions or damage Notify Aeroworks immediately if there are missing or damaged parts and do not proceed with the as...

Page 5: ...h 4 4 40 blind nuts installed 1 Tinted Canopy glued on the canopy base and painted installed on the fuselage by 4 4 40x16mm hex style bolts 4 6 bonded washers for the mounting of the canopy 4 3mm spli...

Page 6: ...stab mount ing 4 6 bonded washer for stab mounting 4 3mm split ring lock washers for stab mounting 4 1 8mm cotter pins 6 4 4 40 3 Left hand and Right hand threaded push rods with nuts and carbon tubes...

Page 7: ...cowl 1 Paper Degree Meter for the Rudder 1 12mm Aluminum Insert 6 Rubber Grommets each for 6mm 8mm 10mm Fuel line and wire guide 10 24 6 35mm Aluminum Engine Stand offs 11 1 C G Buddy 12 1 300x300mm W...

Page 8: ...2 x 48 1 Receiver PCM recommended 1 x Receiver battery min 6 0 volt 1700ma 1 x Ignition battery min 4 8 volt 1700ma 2 switches with charge jacks 22 Gauge min Tools Allen wrenches US and Metric Dremel...

Page 9: ...nd rub in the covering If any bubbles occur your iron may be to hot Reduce heat and work slowly IMPORTANT Go over any and all seams and color overlaps with your iron to assure good adhesion of the cov...

Page 10: ...ered with Ultracote cover ing In case of repairs the colors are Yellow Charcoal White Scheme Cub Yellow 884 Pearl Charcoal 846 White 870 Ultracote Colors Orange Charcoal White Scheme Orange 877 Pearl...

Page 11: ...nge gaps Use covering iron to seal the clear covering snugly into the bottom of the hinge lines as shown for air tight hinge seals Note The clear covering does have a transparent protective backing Th...

Page 12: ...l the hinges have cooled down and the glue has re hardened 1 If the elevator hinges are tight follow the same process as described for the wings Note Once these steps have been completed the hinges wi...

Page 13: ...hown below to begin the servo installa tion Note A 6 extension will also be needed per wing when connecting aileron servos to receiver Note If using a 12 channel radio match boxes or power expander wi...

Page 14: ...m vibration or light tension Note If using a 12 channel radio match boxes or power expander with mixing capabilities it will not be necessary to use a Y harness 7 Remove the balsa stick with the pull...

Page 15: ...e other Y harness 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 11 Install servo in servo we...

Page 16: ...in the mid dle hole of the horn This gives the correct offset to eliminate binding and twisting of the aileron Note It will still be necessary to either program or use a after market type Match Box s...

Page 17: ...ht sides of the control horns to the mounting holes and secure using six wood screws as shown 5 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying...

Page 18: ...ervo arms are parallel to the aileron hinge line Ensure all servos do not fight each other at center or either end point at full deflection Take advan tage of servo programmers and match boxes availab...

Page 19: ...TOR ASSEMBLY 2 Install servo in servo well with the output shaft toward the leading edge of the stab Fish the servo lead through the stab and out of the stab root rib 3 Mark locations of servo mountin...

Page 20: ...lock screws in place Note CA glues have a fast drying time Remember to work quickly 2 Assemble the pushrod and control horn assem bly as shown The ball link goes between the left and right sides of th...

Page 21: ...re the servo connectors with an Aeroworks Safety Clip Ensure the connectors will not come apart from vibration or light ten sion 6 Mount control horn using six wood screws as shown 8 Completed stab an...

Page 22: ...no epoxy gets into the hinge during assembly 3 Mix epoxy in mixing cup and use a tapered stick to apply the epoxy inside the pre drilled holes in the trailing edge of the fin Apply epoxy to one side...

Page 23: ...s epoxy with alcohol wetted wipes 7 Ensure there is minimal to no gap between fin and rudder Allow epoxy to fully cure Note Ensure you have full rudder deflection before epoxy fully cures Rudder Horns...

Page 24: ...o obtain full rudder deflection 4 Use thick CA on each screw prior to installing to lock screws in place Note CA glues have a fast drying time Remember to work quickly 5 Align the left and right sides...

Page 25: ...7 Attach the Y harness to aft rudder servo lead and secure with an Aeroworks Safety Clip En sure the connectors will not come apart from vibration or light tension 8 Attach the Y harness to forward ru...

Page 26: ...through the pre installed cable exit tube in the tail of the fuse toward the front Repeat for other side 13 Tie off or tape rudder cables to keep them from pulling into fuse 14 Pull the rudder cables...

Page 27: ...coupler as shown below 16 Thread the brass swag tube onto the pull pull cable followed by the threaded coupler 17 Thread cable back through the brass swage tube as shown 18 Loop the cable back through...

Page 28: ...ut off excess cable as shown 21 A drop of thin CA may be applied to the swage tube to help secure the cable Rudder Servo Linkage Installation 1 Gather the supplied rudder linkage pushrod and ball link...

Page 29: ...rvo arm to the aft rudder servo as shown below 5 Tape the rudder balance tab to the top leading edge of the vertical fin in the neutral position as shown This ensures the rudder is straight when the c...

Page 30: ...adjustment wrench adjust the pushrod length to prevent the servo from binding 8 Finished rudder linkage assembly shown below 9 Adjust the tension of the pull pull cables until they are tight Note Due...

Page 31: ...ering springs are installed 2 Gather the tail wheel parts shown below 1 Aluminum Tail wheel assembly 3 tail wheel mounting screws 1 aluminum steering tiller 2 tiller mounting screws and 2 steering spr...

Page 32: ...thick CA on tail wheel strut mounting screws before inserting in the pre drilled mounting holes on the bottom rear of the fuse 7 Mount the tail wheel strut using three wood screws 8 Attach the steeri...

Page 33: ...ring 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...

Page 34: ...AR AND WHEEL PANT INSTALLATION 2 Remove the Phillips head screws holding the landing gear cover in place 3 Align mounting holes in gear with pre installed blind nuts in mounting plate of fuse Note Bol...

Page 35: ...gear strut is facing toward the rear 6 Reinstall the landing gear hatch cover 7 Install the axle into the gear strut with nylon lock nut Only snug tighten at this time 8 Align the wheel pant mounting...

Page 36: ...bolts 11 Install the wheel and outer wheel collar Use blue Loctite on the wheel collar set screw before final tightening 10 Install the inner wheel collar on the axle Use a drop of blue Loctite on the...

Page 37: ...37 13 Final gear assembly with gear cover installed shown below...

Page 38: ...Aluminum spacers are included to set the proper stand off distance for your en gine 3 Locate the laser cut engine mounting template for the DA 100 Note If other engines are used the templates may be m...

Page 39: ...ter drilling is finished re move template from firewall 6 Mark a location for the ignition pickup to pass through the firewall 7 Use a 1 4 drill bit to drill the ignition pickup hole in the firewall 8...

Page 40: ...allation is now complete Throttle and Choke Installation 1 Gather the left and right plywood throttle and choke servo mounting trays the throttle and choke servos and pushrod parts 2 x 4 40 metal rods...

Page 41: ...bottom of the engine box as shown 4 Use a rotary cutting tool to cut out the throttle servo mounting hole Note Cover engine with a towel or cloth or use masking tape to protect from any debris gettin...

Page 42: ...uretor at half throttle measure and mark the end of the throttle pushrod wire that will be inserted into the threaded coupler as shown 9 Cut the throttle pushrod to the proper length 10 Gather the sol...

Page 43: ...4 40 ball links and secure Power up the receiver and throttle servo and adjust pushrod for proper op eration Ensure the servo or rod does not bind or jam at closed or full open positions 1 A none sol...

Page 44: ...installation shown below 3 Use a rubber grommet supplied to protect the cowl from the manual choke pushrod Manual Choke Installation 1 Assemble the rod as shown below Follow the previous steps on pus...

Page 45: ...her the ignition module ignition battery switch and mounting hardware as shown 3 Position the ignition module inside the engine box to allow both of the spark plug leads to exit and properly connect t...

Page 46: ...the ignition battery using the foam pad with a nylon tie as shown 8 Thread ignition connector through firewall and connect ignition timing connectors with an Aeroworks Safety Clip Ensure the connecto...

Page 47: ...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: ...the fuel tank and Two for the smoke tank Solder a brass fuel barb to the fuel line pick up tube This will keep the weight of the fuel clunk from pulling the fuel line off the brass tube Note No brass...

Page 49: ...and bend upward Air vent tube should rest as close to the top of fuel tank as possible Without touching the top of the tank 7 Install the fuel tubing and clunk Secure the fuel tubing with nylon ties t...

Page 50: ...upplied but are available through Aeroworks 2 Install a short piece of fuel line and the fuel T to the fuel pick up tube Note Using a heat gun and or soapy water solu tion to soften the fuel line will...

Page 51: ...g flight 5 Thread nylon ties under tank mounting plate and center in position 6 Install foam rubber pad for fuel tank to rest on Foam rubber will help prevent fuel from foam ing or getting air bubbles...

Page 52: ...g Secure all fuel lines with nylon sip ties Note It is recommended you always use a fuel filter in the carburetor line 10 Gather the supplied fuel filler dot and drill bits as shown below Note We reco...

Page 53: ...ecurely mount the fuel dot Be careful not to get any CA inside of the dot itself 14 Slide fuel filler line through the fuel dot and in stall the stopper on the end as shown below 15 Route the vent lin...

Page 54: ...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 Using rubber...

Page 55: ...move the canister tunnel cover as shown be low 3 Leave the canister tunnel cover off while flying This will help provide better cooling for the en gine 4 Install the muffler on the motor Blue Loctite...

Page 56: ...e 7 Use the bottom mounting bolts to keep the tem plate secure This will provide a consistent point of reference when marking and cutting the cowl 8 Lift the template material so that it contacts the...

Page 57: ...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 Note Take care and test painted areas prior to...

Page 58: ...0x16mm button style hex head bolts 2 6 32 hex head bolts 4 6 bonded washers 15 Using a covering iron seal the covering around the air exit holes as shown below 16 Use a hobby knife to remove the cover...

Page 59: ...covering around the hot air exit holes 3 Remove the covering over the stinger exit This will allow the canister stingers to exit the fuse CANISTER COWL INSTALLATION Canister Installation Gather the ca...

Page 60: ...ister mounting bracket position shown be low Note Mounting bracket can be moved forward to accommodate shorter length canisters 6 Test fit canister mount in the fuse If necessary sand canister mount t...

Page 61: ...clamps in accordance with manufactures instructions 11 Slide the canisters into the canister tunnel as shown below 8 Reinstall the canister mount in the fuse Allow epoxy to fully cure before moving o...

Page 62: ...ts provided with your engine Use blue Loc tite to secure the bolts 13 Finished canister installation shown below 14 Mark air exit slots on bottom using the supplied template as shown 15 Use a dremel t...

Page 63: ...secure the receiver battery in place Install the Velcro straps as shown below 2 Install the receiver regulator following the manufacturers instructions 4 Use the supplied foam to isolate the receiver...

Page 64: ...as the receiver battery Refer to receiver manufac tures instructions for specific receiver mounting 7 Apply baby powder or corn starch to antenna wires to assist getting antennas into their guide tub...

Page 65: ...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...

Page 66: ...use or wing root wood 3 Gather the 4 4 40 stab mounting bolts and 4 6 small rubber backed washers 4 Slide the stab tubes in the fuse stab tube sleeves short tube front long tube rear Slide the stabs o...

Page 67: ...p bolts from coming loose from normal engine vibration 7 Secure bottom section of cowl with 4 40 x 16mm button head bolts and 6 bonded washers 6 Secure top section of cowl with 6 32 x 16mm hex head bo...

Page 68: ...ee or credit card Windex or Application fluid like Rapid Tac Also a solution of 1 drop of dish detergent to a cup of water sprayed on the model will as sist in proper positioning Note Clean surface an...

Page 69: ...ansfer tape until decal placement is complete Decals supplied with the kit may vary from the photos below Decal application steps will be similar 6 Remove backing from Clear transfer tape 7 Apply clea...

Page 70: ...ansfer tape to top of decal 9 Peel backing from decal 10 Spray model surface with application fluid Windex or soapy water solution 11 Spray back side of decal with application fluid Windex or soapy wa...

Page 71: ...cal smooth and remove all excess application fluid Let decal set until dry enough to be able to remove transfer tape with out removing decal Do not leave until completely dry or transfer tape will be...

Page 72: ...gs away from fuse and install the CG Buddy on the wing tube and front rotation dowel as shown The cable attachment should be on the top side of the wing Make sure the CG Buddy is se curely latched to...

Page 73: ...he batteries installed and READY TO FLY Try to balance the model by moving the batteries and receiver before adding any ballast IMPORTANT The CG Buddy is not adjustable and is set to bal ance the airp...

Page 74: ...hat is fine to start with After you are comfortable adjust the CG to suit your flying style in small steps especially when shifting the CG toward the tail Move the battery or add small stick on weight...

Page 75: ...Aileron throw measured in degrees at widest point of the aileron 3 Use the supplied flight control deflection meter to measure the throws in degrees It is recom mended you level the model 4 Elevator...

Page 76: ...of the boost tab as shown below 6 Gather the Rudder Throw Meter Supplied and scotch tape 7 Slide the throw meter under the rudder boost tab Center the throw meter on the rudder using the centering mar...

Page 77: ...3 4 or 22 down For 3D flying use the following throws 3D Rate Aileron 4 1 4 or 40 up 4 1 4 or 40 down Rudder N A or 45 left N A or 45 right Full rudder deflection is typically recommended for all out...

Page 78: ...olts hatch bolts servo screws control horn bolts wheel collars and clevis keepers are tight and secure Use Loctite were necessary Covering Check all seems and overlaps are se cure and have not lifted...

Page 79: ...e is a list of some of the more popular aerobatic and 3D maneuvers you can try Loops and rolls Knife edge flight Stall turns Snap rolls 2 4 and 8 point rolls Slow rolls Spins upright and inverted Flat...

Page 80: ...___________________________________________________________________________ ___________________________________________________________________________ ________________________________________________...

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