PAU Edge540 Instruction Manual Download Page 2

 

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We believe you will find this to be one of the finest flying aircraft on the market.  Most modelers will find 
assembly of this aircraft simple and straightforward.  We recommend the builder follow the step-by-step 
instructions to achieve the best performance and to ensure nothing was over looked.  This manual also includes 
tip sections throughout that may help you in key areas during assembly.  Please familiarize yourself with this 
manual before assembly.   
 
 

This manual is broken down into ten chapters for simplicity: 

 

Chapter 1 -

 Parts Inventory 

Chapter 2 - 

Preparation for Assembly 

Chapter 3 -

 Landing Gear and Tail Wheel Assemblies 

Chapter 4 - 

Canopy and Fuselage Hatch 

Chapter 5 - 

Engine Installation 

Chapter 6 - 

Cowling installation 

Chapter 7 -

 Rudder Installation 

Chapter 8 -

 Hardware Installation 

Chapter 9 -

 Radio and Control Surface Setup 

Chapter 10 -

 Final Inspection and Pre-Flight 

 

 
Additional items needed to complete this aircraft, which are not included: 

 

 

An engine, within the recommend range, and propeller 

 

8 channel computer radio and receiver recommended 

 

Batteries and switches (with regulators if using Ion batteries) 

 

Six aileron servos rated at least at 150oz of torque 

 

Four elevator servos rated at least at 200oz of torque each! 

 

Two or three rudder servos rated at least at 800oz of torque combined 

 

One throttle servo with push rod and links 

 

Optional choke servo with push rod and links 

 

One fueling dot or fueling device 

 

3 to 4 feet of fuel tubing 

 

Foam rubber 

 

5” inch spinner 

 

30 to 45 minute epoxy 

 

A bottle of thin CA 

 

Covering iron 

 

Various modeling tools for assembly 

 

½ inch low tack masking tape 

 
Using fewer servos then specified will not be covered under warranty!  This is a large aircraft with very 
large control surfaces that require better than average servos.   
 
As with any aircraft this size, more care needs to be taken when flying.   Aircraft this size susceptible to 
damage or failure due to high G loading due to excessive speed during hard maneuvers.  

Watch your 

speed!

  Since it’s an Edge, it wants to rotate more easily from normal flight to fully stalled conditions which 

if not careful can over stress the airframe.  This is one of the reasons Edge are so popular for 3D 
 

Summary of Contents for Edge540

Page 1: ...the podium for some time to come The PAU Edge is no different Designed with 2963 sq inches of wing area while keeping the total weight down has made this aircraft a true performer All wood constructio...

Page 2: ...nd propeller 8 channel computer radio and receiver recommended Batteries and switches with regulators if using Ion batteries Six aileron servos rated at least at 150oz of torque Four elevator servos r...

Page 3: ...embly 1 Canopy 1 Carbon fiber wing 1 Carbon fiber stabilizer tube 4 Nylon wing retention bolts 10 H9 titanium pushrods turnbuckles 1 set of Dubro wheel collars 1 pair of Dubro wheel axels 1 HD Dubro p...

Page 4: ...sure a scratch free finish Place an to ensure task completion Go over you model as necessary with a covering iron to insure all joints seams and corners are sealed properly Use your iron to ensure the...

Page 5: ...refully cut through the covering and into the laser cut lines in the fuse Remove the covering and carefully remove the wood within the frame Test fit the windows as some slight trim work may be requir...

Page 6: ...ack marked wheels Fuselage Rudder Carbon Fiber Tail wheel assembly Not Provided and a 9 16 inch wrench Blue loc tite Allen wrench for wheel collars White wood glue such as Elmer s or Epoxy Fasten the...

Page 7: ...ssion nuts Now lets get the tail wheel assembly installed Once the mains are on find the holes for the tail wheel assembly and open Once the mains are on find the pre marked holes for the tail wheel a...

Page 8: ...ng the end on the rubber grommets of the servo Mark the drilling location for the 4 40 bolts Drill the holes for the 4 40 bolts in the wheel pants at the locations you ve marked Apply some white wood...

Page 9: ...opy to the fuselage access hatch to determine screw locations Mark four to eight evenly spaced locations for the screws on each side Double check to ensure all the marked screw locations will go into...

Page 10: ...e you can use the pre marked firewall this may by slightly off due to variances when cutting the cowl from the molds DA 150 170 installation The firewall is pre marked so you ll just need to center yo...

Page 11: ...you will end up with a professional installation that will make an impression at the field Close the choke and place a piece of tape over the carburetor inlet and exhaust outlet to keep out any dust w...

Page 12: ...e holes of the trailing edge Apply epoxy to one side of the hinges and insert them into the holes figure 73 74 and 75 11 Apply epoxy into the leading edge holes of the control surface and the other si...

Page 13: ...ol surface fully deflected up and iron it in place Check to make sure you still have full surface travel once you have completed figure 78 79 and 80 Tip 5 Optional step After your epoxy has cured it w...

Page 14: ...elevators Two or three servos for rudder equaling 800oz One throttle servo 70oz or better Ten 1 5 aluminum servo arms One or two 3 arms to tie rudder servos One 4 offset rudder servo arm One Fuel dot...

Page 15: ...position Screw in your two HD ball links onto the counterclockwise ends of the 2 5 H9 push rods and screw the other end into the control horn Ensure everything is still centered Don t forget to add lo...

Page 16: ...l servo arms to tie the two or three servos together as well as a servo matching devise Install your pull pull cable using the 60lbs leader provided Please discard the wire provided with the Dubro pul...

Page 17: ...ach side of the fuse They will both accept HD standard switches Mount your switches at this time Install the fuel filling device in a location of your choice In this case we installed it just behind t...

Page 18: ...the wings installed mark the anti rotation pins inch from the fuselage side Remove the wings and drill a small hole in the anti rotation pins You can find appropriate sized hitch pins at most local ha...

Page 19: ...70 expo 45 degrees for elevators with 40 to 70 expo 45 degrees for rudder with 30 to 70 expo or as much as you can stand for hardcore flyers CG Range is 7 1 2 to 9 inches or center of tube Place an to...

Page 20: ...ardware Gently tug on each surface to make sure the hinges are properly bonded Check the four 4 40 horizontal stabilizer fasteners and ensure they re in place and secured Check all servos for mounting...

Page 21: ...r throttle management and avoid high speed when executing high stress maneuvers such as Walls Parachutes and Blenders As a general rule the throttle must be at idle position whenever the nose is point...

Page 22: ...22 Throw Template If printing from Adobe turn off page scaling Cut out around all the dotted lines...

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