Extreme Flight EDGE 540 Assembly Manual Download Page 33

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NOTE: There are three servo locations in each wing panel. You can use one servo in the center

location, two in the inner and outer locations, or three servos. Be *extremely careful* if using only

one aileron servo, most twin-cylinder engines 100CC and up produce enough power to blow back or

even a flutter a single aileron servo. Flutter can destroy your aircraft and is not covered under any

warranty. We recommend two heavy duty metal gear aileron servos per wing.

NOTE: Pull Strings are pre-installed in your wing panels to facilitate pulling servo leads through the

wing panel.

Summary of Contents for EDGE 540

Page 1: ...ent 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...

Page 2: ...lips Screwdriver Set Metric Allen Wrenches Scissors Small Pliers Wire Cutters Adjustable wrench Masking tape Drill and drill bits Threadlocker Blue Loctite Optional Heat gun and covering iron Dremel tool Assembly Instructions Read completely before starting assembly UNPACK Unpack your airplane and examine the components Check for damage of any kind If you have damage please contact Extreme Flight ...

Page 3: ... at seams and corners or even by melting it The covering will shrink at low temperature with patient application of heat Wrinkles in the covering DO NOT affect flight performance If you must shrink on a color seam use the iron and go slowly and carefully to avoid any pulling or lifting at the seam Remove the canopy before attempting to use heat on your covering The canopy is made of thermo activat...

Page 4: ...from forward fuselage areas 1 Front Anti rotation pin 2 Wing Safety Pin 3 Wingtip Factory Cut 4 Cut either one for aileron servo leads 5 Wing bolt 6 Rear Anti rotation pin Next remove covering for the horizontal stabilizer bolts and front stab carbon tube ...

Page 5: ...Remove tail wheel assembly set screws one at a time and re torque using blue loctite Install tail wheel assembly using 3x 4 40 bolts and washers Use blue loctite on the bolts ...

Page 6: ...ardware bag The axles come pre drilled and the pin is included in the hardware bag To get the proper spacing you will need 1 collar and one washer on the inside of the axle and then one washer on the outside of the axle as shown ...

Page 7: ...sed above Now attach the assembled wheel and pant to the landing gear with the included 4 40 bolts and nylon lock nut Remember to slide the landing gear cuffs on before attaching both wheel pants as well The screws holes should face towards the ground ...

Page 8: ...This is what the finished assembly should look like Make sure the wheel is centered in the pant If adjustment is needed you can rearrange the washers and collar to achieve it ...

Page 9: ...ing gear to the plane with the included 4mm bolts washers and nylon lock nuts Use the Phillips head 3mm screw to attack the cuffs to the landing gear The cuffs can also be used to hold the landing gear cover plate in place ...

Page 10: ...r tuned pipes We provide the parts for a variety of setups Vented covers are included for the tunnel which can be installed if desired If using stock mufflers the covering over the tunnel can be left intact if desired First if desired the entire tunnel can be blocked off with this blockoff plate Install with epoxy glue and wood screws ...

Page 11: ...included panels There are various canister pipe mounts included drilling template throttle servo box and covers for various places on the airframe Remove the covering over the vent holes on the cover plates as shown ...

Page 12: ...wood screws This is a picture from the 104 Slick so the panels may look slightly different Your kit includes two different kinds of ball links The top one is used in between the phenolic control horns The bottom one with the integrated spacer is used on the servo arm end ...

Page 13: ...s have left hand threads on one end and right hand threads on the other Look very carefully to determine left and right before screwing on your links Because the links are opposite threaded on each end you can use the included link wrench in your kit to change the pushrod length after they are installed on the airplane ...

Page 14: ...ic fiberglass style The horns for the elevators and ailerons are identical The rudder horns are longer double sided Elevator and Aileron horns are installed as follows Using sand paper or something similar rough up the areas that will be glued as shown ...

Page 15: ...g so will make installing the fully assembled horn much easier Assemble the control horn as shown Temporarily install in the control horn and cut out around the base of it as shown Next glue in the control horn using either 30min epoxy or Gorilla Glue This same process is used for the elevators and ailerons ...

Page 16: ...m for rudder servo location Pull pull cables are already installed in the fuselage for ease of installation of this system View of the contents of the rudder hardware bag Installing the rudder control horn Assemble control horn as shown ...

Page 17: ...w the base plate leave the horn in place and attach the other ball link Next push the control horn in the slot in one direction until you can see the holes in the center Apply glue to the area and push the arm back to center Make sure it is perfectly centered using a ruler The pics below are from the 104 slick but accurately illustrate this process ...

Page 18: ...t install the rudder onto the fuse using the included hinge pin Install rudder onto vertical stabilizer and fuselage slide rudder hinge wire into rudder from the top and down into the recess slot on top of rudder as shown ...

Page 19: ...rudder hinge wire at bottom Trim wire as needed Pull pull cables are already installed into your fuselage Complete rear end of pull wires on both sides as shown using double crimps and looping wire through crimps as shown ...

Page 20: ...s A typical servo installation with one 3 double sided offset arm is shown Make cables snug but not banjo string tight Only snug is necessary Match your servos properly according to the instructions of your radio equipment Here is a pic from the 104 Slick that illustrates a dual rudder servo setup in the pull pull configuration ...

Page 21: ...Install your elevator servo into the horizontal stab of your choice as shown Yes this will take some time and you will need a long screwdriver Be patient ...

Page 22: ...own You may want to lengthen the slot depending on which arm you choose to use A 1 75 arm is used in this picture Install both carbon stabilizer tubes into fuselage and slide stabs on all the way Attach with 4 40 screws and washers as shown If stabs are to be permanent use loctite ...

Page 23: ...Included engine mounting hardware The location of the motor mounting bolts are etched into the firewall but a template is included as well This template is for DA twin cylinder engines and 3W ...

Page 24: ...old in place Hole size is 1 4 Use large washers on the back along with the nylon lock nuts Also shown here is the throttle servo mounted You can used the included wooden servo rings to give the servo mounting screws more wood to bite into ...

Page 25: ...plus one washer should give you the desired spinner to cowl gap An extra washer may need to be added or this washer can be removed depending on the spinner gap you prefer DA 100 and DLE 111 mounted with shorter standoffs ...

Page 26: ...ed throttle linkage parts NOTE The link length included is approximate it works well on DA 100 and DLE 111 for DA 120 which mounts farther forward you may need a longer link for best geometry Installing link ...

Page 27: ...low you to mount a choke servo in any location However we use and recommend a simple manual pull type choke linkage which extends through the bottom of the cowl This linkage is not included but is easily make from a short piece of steel wire or an unused section of pushrod Measure and cut the needed areas for your specific muffler setup ...

Page 28: ...In this build we decided to close off the tunnel and cut cooling slots in the bottom of the cowling ...

Page 29: ...ake sure that the fuel line cannot come into contact with the muffler In the picture above we used flame retardant heat shrink over the tubing just in case it would ever touch the muffler Next attach the bottom half of the cowling using the included 4 40 screws and washers ...

Page 30: ...e We also highly recommend baffles to direct airflow over large electric motors and twin cylinder gas engines Below is an example of what this baffling may look like We recommend using balsa or Depron foam ...

Page 31: ...Here is an example manual choke setup using a spare pushrod ...

Page 32: ...Here is an example layout of the RXs and where the RX packs would go ...

Page 33: ...only one aileron servo most twin cylinder engines 100CC and up produce enough power to blow back or even a flutter a single aileron servo Flutter can destroy your aircraft and is not covered under any warranty We recommend two heavy duty metal gear aileron servos per wing NOTE Pull Strings are pre installed in your wing panels to facilitate pulling servo leads through the wing panel ...

Page 34: ...install the wings the holes for the spring clips will be tight to the fuselage side This is by design use a small tool to clearance this fit before installing the clip After a few cycles this will settle in at the proper clearance Optional wing tip accessories Installed using 4 40 screws ...

Page 35: ...nylon thumbscrews These thumbscrews require no tools to install or remove Please inspect these screws frequently for wear and fatigue Throws High Rate Ailerons 45 degrees Elevator 55 60 degrees Rudder Maximum throw available without interference High rate controls typically use 50 75 exponential Throws Mid Rate if used Ailerons 30 degrees Elevators 30 degrees Rudder Maximum throw Throws Low Rate A...

Page 36: ...you the very best with your new 106 Edge The preferred CG for this plane is at 5 5 back from the leading measured at the wingtip This is the recommended CG to start with and can then be tuned for a specific style of flying ...

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