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INSTRUCTIONS

WARNING

A radio-controlled model is not a toy and is not intended for persons under 16 years old.  Keep

this kit out of the reach of younger children, as it contains parts that could be dangerous.  A radio-

controlled model is capable of causing serious bodily injury and property damage.  It is the buyer's

responsibility to assemble this aircraft correctly and to properly install the motor, radio, and all other

equipment. Test and fly the finished model only in the presence and with the assistance of another

experienced R/C flyer.  The model must always be operated and flown using great care and common

sense, as well as in accordance with the Safety Code of the Academy of Model Aeronautics

(www.modelaircraft.org).  We suggest you join the AMA and become properly insured prior to flying

this model.  Also, consult with the AMA or your local hobby dealer to find an experienced instructor in

your area.  Per the Federal Communications Commission, you are required to use only those radio fre-

quencies specified "for Model Aircraft."

LIMITED WARRANTY

Carl Goldberg Products has inspected and certified the components of this aircraft.  The company urges the buyer to perform his

own inspection, prior to assembly, and to immediately request a replacement of any parts he believes to be defective for their

intended use.  The company warrants replacement of any such components, provided the buyer requests such replacement with-

in a period of 90 days from the date of purchase and provided the defective part is returned, if so requested by the company. 
No other warranty, expressed or implied, is made by the company with respect to this kit.  The buyer acknowledges and under-

stands that it is his responsibility to carefully assemble the finished flying model airplane and to fly it safely.  The buyer hereby

assumes full responsibility for the risk and all liability for personal or property damage or injury arising out of the buyer's use of the

components of this kit.

CARL GOLDBERG PRODUCTS, LTD.

P.O. Box 818 Oakwood GA 30566  Phone #678-450-0085 Fax # 770-532-2163  www.carlgoldbergproducts.com

© Copyright 2005 Carl Goldberg Products LTD

TM

77” Edge 540 ARF

Summary of Contents for Edge 540 ARF

Page 1: ...use only those radio fre quencies specified for Model Aircraft LIMITED WARRANTY Carl Goldberg Products has inspected and certified the components of this aircraft The company urges the buyer to perform his own inspection prior to assembly and to immediately request a replacement of any parts he believes to be defective for their intended use The company warrants replacement of any such components ...

Page 2: ...e servo mounting trays wing hold down blocks Firewall etc Also during the course of shipping from the manufacturer to our facility in the United States it is not uncommon for the aircraft to experience several changes in climate This may cause the iron on covering to develop wrinkles This is not a fault of the manu facturer Please take a few minutes with your heating iron and heat gun to iron down...

Page 3: ...ommend ed If CA does happen to get into the eye hold lid open and flush with water only Seek immediate medical atten tion CONSTRUCTION TIPS IMPORTANT ALWAYS READ A FEW STEPS AHEAD This will alert you to coming instructions and will help you plan accordingly COVERING The 77 Edge 540 ARF is covered in a premium polyester film chosen by many of the world s top flyers for its beau ty toughness and eas...

Page 4: ...Thread the nylon adjustable control horn onto the bolt Note Thread the side that you can see the cut threads in the nylon onto the bolt 2 With the aileron servo in place make a mark on the aileron at a 90º degree angle to the trailing edge and in line with the servo Look for the control horn hard point under the cov ering This is the location for the control horn 4 AILERON CONTROL HORN INSTALLATIO...

Page 5: ...on Working with 1 hinge at a time place a dab of epoxy and insert the hinge half way into one of the aileron holes Repeat for each of the other hinges for that aileron 5 Working quickly place some epoxy on the second half of each hinge and insert the aileron into the wing Slide the aileron toward the wing until no gap remains between the aileron and the wing When satisfied with the alignment flex ...

Page 6: ...ing flying always tape them securely together with electrical tape 3 Tape the end of the plug to the root rib Repeat for the other wing half Aileron Servos Pushrods 1 COLLECT THE FOLLOWING ITEMS 4 4 40 X 3 1 8 PUSHRODS THREADED BOTH ENDS 4 4 40 CLEVIS 4 SILICONE CLEVIS RETAINERS 4 4 40 nuts 3 Repeat for the other three servos 2 Screw the 4 40 x 3 1 8 pushrod into the nylon control horn fitting on ...

Page 7: ...ding gear legs 3 Mount the axle to the landing gears 7 FUSELAGE HATCH The top front half of the fuselage is a hatch Remove the 4 40 socket head bolts on the side of the fuse lage to disengage the hatch 2 Insert the gear legs through the slots in the fuselage side Use the six 6 32 x 1 bolts to secure the gear The blind nuts are already installed in the fuselage Be sure and use thread lock on the bo...

Page 8: ...der and four hinges Trial fit the hinges to make sure they all go up to the hinge pin in rudder and fin 2 Trial fit the rudder in place on the fin Make sure the hinge line is tight and the counter bal ance does not rub on the top of the fin Insert a piece of wire into the outlet hole for the rudder cable holes are just below the ele vator servo cutout and make a mark on the rudder in line with the...

Page 9: ... wheel axle 1 1 rubber tail wheel 1 1 8 wheel collar 2 bracket collars 2 nylon horn brackets 2 3mm screws 2 2mm x 1 threaded rods 2 One of the bracket collars has two holes threaded into it one on each side This one is the top one Put the bottom bracket collar on the axle and insert it through the spring bracket Put the top collar bracket on top and tightened the two set screws 3 Screw one of the ...

Page 10: ... the same method we did on the ailerons and rudder Stabilizer and Elevator Installation 1 Collect the following parts 2 stab halves 2 elevator halves 8 hinges 2 6 32 x 3 1 2 control horn bolts 2 nylon nuts 2 nylon washers 2 adjustable control horns 2 The two inboard hinges will have to be cut off 1 2 because of the rear aluminum tube Trial fit the elevators to the stab and make sure all hinges wil...

Page 11: ...ble horn should be screwed 1 up the screw on the horn 3 Screw the control rod into the nylon horn and screw the 4 40 nut then the clevis on the other end Slide the silicone keeper on the clevis before installing it Center the servo with the radio and adjust the pushrod and clevis till the elevator is neutral Repeat for the other servo 4 Make sure both elevators are aligned even with each other Tig...

Page 12: ...ble swages then through one of the rigging couplers Loop the cable back through the cable swage Take the end and loop it back around the cable swage and go through the swage again 2 Screw one of the rigging couplers without a nut into the control horn on the rudder Cut the braided cable into two equal lengths 3 Pull the cable tight and crimp the swage Repeat for the other side 4 Thread the cables ...

Page 13: ...or adjustment you will need to tighten the cables 6 Mount the rudder servo in the hole provided in the servo tray You will need a double sided heavy duty servo arm on your rudder servo 7 Connect the two clevises to the output arm on your servo Tail Wheel Springs 1 Loop the straight end of the spring through the pushrod connector on the rudder horn Use about 1 2 the length of the straight wire and ...

Page 14: ...ough We will not warranty any structural failures do to neglect or accidents 1 You will find both the horizontal and vertical lines marked on the firewall The vertical line is off set to compensate for the 2 degrees right thrust Mark your motor mount location from these marks The front of the cowl is 5 13 16 from the fire wall Caution Always use thead lock on any bolt that is threading into metal ...

Page 15: ...of the holes on the firewall Drill a 25 64 hole at the four locations 4 Using the 3mm mounting bolt and washer pull the blind nuts into the firewall 5 Mount the engine using the four 3mm x 25mm screws and flat washers Be sure and use thread lock on the bolts Cowl Mounting 1 Collect the following items 1 cowl 4 4 40 x 1 2 screws 4 nylon cup washers 2 Take four strips of paper and tape to the side o...

Page 16: ...ned transfer the location of the mounting holes from the paper to the cowl Remove the cowl and drill a 1 8 hole at the four locations 5 To locate the needle valve outlet hole tape a piece of paper to the side of the fuselage with the needle valve extension through the paper 6 Remove the needle valve reinstall the cowl using the bolts and transfer the hole location to the cowl Remove the cowl and d...

Page 17: ...plate 3 Mount the servo in the tray using the hard ware supplied with the radio Glue the servo mount to the fuselage side on the same side as the throttle arm on your engine Glue in at a height that will match your throttle arm 4 Locate the ez connector and remove the nut 5 Attach the ez connector to your servo arm Put a drop of CA on the nut to make sure it does not come loose 1 Collect the follo...

Page 18: ...e 3 aluminum tubes 2 Insert the three aluminum tubes into the cap assembly There should be two short tubes that extend out the front and back of the cap about 1 2 to 5 8 The third line is the vent and should be bent at an angle so it touches the top of the tank when installed 6 Drill a 5 32 hole in line with your throttle arm It may be necessary to make an offset bend in the throttle rod to make i...

Page 19: ...e location of the tank along the top edge Measure down from the line and allow for the thickness of the tank floor and glue the 3 8 square balsa to each side of the fuselage 8 If you use a gas motor or motor with a pump the tank floor can be installed in the rear most position which will put the tank closer to the CG 6 Glue the tank support floor in place on top of the 3 8 square rails 7 Install t...

Page 20: ...iver and Switch Installation 1 Switch mount positions are provided on both sides of the fuselage either can be used 2 A mount for the receiver is provided just behind the servo tray and under the rudder cables ...

Page 21: ... wing tube into each wing panel If very tight try a little wax on the wing tube work it in and out till it frees up Fit both wings in place and hold in place with the 1 4 20 nylon bolts Note The bolts are sent full length you will prob ably want to cut them down to about 3 4 to 1 to make them easier to install 3 Install the battery pack according to where you need the weight to make the CG correct...

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