3DHS 92 Edge 540 V2 ARF User manual

92" Edge 540 V2 ARF
Assembly Manual
Copyright 2018 Extreme Flight RC

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Please take a few moments to read this instruction manual before beginning
assembly. We have outlined a fast, clear and easy method to assemble this aircraft
and familiarizing yourself with this process will aid in a quick, easy build.
Please read the following paragraph before beginning
assembly of your aircraft!
THIS IS NOT A TOY! Serious injury, destruction of property, or even death may
result from the misuse of this product. Extreme Flight RC is providing you, the
consumer, with a very high quality model aircraft component kit, from which you,
the consumer, will assemble a flying model. It is beyond our control to monitor the
finished aircraft you produce. Extreme Flight RC will in no way accept or assume
responsibility or liability for damages resulting from the use of this user assembled
product. This aircraft should be flown in accordance with the AMA safety code. It is
highly recommended that you join the Academy of Model Aeronautics in order to be
properly insured and operate your model at AMA sanctioned flying fields only. If
you are not willing to accept ALL liability for the use of this product, please return it
to the place of purchase immediately.
Extreme Flight RC, Ltd. guarantees this kit to be free of defects in materials and
workmanship for a period of 30 DAYS from the date of purchase. All warranty
claims must be accompanied by the original dated receipt. This warranty is extended
to the original purchaser of the aircraft kit only. Extreme Flight RC in no way
warranties its aircraft against flutter. We have put these aircraft through the most
grueling flight tests imaginable and have not experienced any control surface
flutter. Proper servo selection and linkage set-up is absolutely essential. Inadequate
servos or improper linkage set up may result in flutter and possibly the complete
destruction of your aircraft. If you are not experienced in this type of linkage setup
or have questions regarding servo choices, please contact us at
[e-mail] or 770-887-1794. It is your responsibility to ensure the
airworthiness of your model.
Congratulations on your purchase of the 3DHS 92" Edge 540 V2 ARF!
The original 3DHS 92" Edge 540 was a legendary airframe among devotees of 3D
Aerobatics. It was beloved due to its ability to be both stable and gentle for 3D
newbies yet aggressive and satisfying for the more experience flyer. Now the 3DHS
Edge 540 has been updated to current specifications with generous use of carbon and
composites to strengthen the airframe while keeping the weight low. The cowl has
been remodeled to the latest high performance racing design borrowed from the
Edges that currently dominate the air race series. Little has changed however in the
basic aerodynamic package that the Edge is built around as it has more than proven
itself. The DA 70 or Xpwr 60cc motor are both excellent choices for the 92” Edge.

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Items needed for completion:
•Masking tape.
•Hobby knife with #11 blades.
•Thin and medium CA. We highly recommend Mercury M5T thin and M100XF
medium formulas as well as the Mercury glue tips.
•30 minute epoxy. Pacer Z-poxy is a long time favorite.
•Pacer Formula 560 Canopy Glue
•Blue Loctite.
•Electric drill with an assortment of small drill bits.
•Flat head and Phillips head screw drivers.
•Standard and needle nose pliers.
•Side cutters.
•Metric ball driver or allen key set.
•Sanding block and sandpaper.
•5 x METAL GEARED servos with a minimum of 400 oz/inches of torque. MKS
HV777A+ or HBL 380 recommented
•Extreme Flight aluminum servo arms: 2 x 1.5 inch arms for aileron, 2 x 2 inch
arms for elevators and 1 x 4" dual arm for the rudder.
•2 x 12” Servo Extensions for the Ailerons.
•1 x 12” Servo Extension for throttle or ESC
•2 x 48” Servo Extensions for the elevator.
•Xpwr 60cc brushless outrunner motor
•Blazing Star Standard XL standoff kit for electric motor mounting
•Castle Creations 160 HV ESC.
•Receiver battery
•2 x 6S 5000-5500 mah LiPo battery hooked up in series for 12S operation
•Xoar 24 x 12 PJN electric prop.
•DA-70 with mufflers if using a gas engine.
•Blazing Star DA 70 stand off.
•Flowmaster 17 or 24 oz. fuel tank.
•EF 4.5" CARBON FIBER spinner with aluminum backplate.

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Let’s get started!
Wing assembly
1. Locate the 2 wing panels as well as the composite aileron control horns and
base plates. Use a soldering iron or sharp hobby blade to remove the covering
over the slots for the aileron horn and aileron servo mount as shown. Make
sure you are doing this on the bottom of the wing and aileron!

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2. Scuff the portion of the horn that will glue into the aileron and secure with 30
minute epoxy. Wipe away any excess glue with an alcohol soaked rag. Insert
the ball link between the horns to ensure proper alignment while the glue dries.
3. Inspect the hinges and make sure that each hinge is seated properly. Adjust
any hinge holes that are impeding movement. Remove all of the hinges from
the wing and aileron. Mix a generous batch of 30 minute epoxy. Use a zip tie
or an old pushrod to thoroughly coat and fill the hinge holes in the wing with
epoxy. Coat one side of each hinge with epoxy and insert it into the wing
taking great care to make sure it is centered properly. Wipe away any excess
glue with an alcohol soaked rag or paper towel. Once all hinges are installed in
the wing set it aside to dry.
4. Once dry use the same procedure to fill the hinge holes in the aileron with
epoxy. Coat the protruding hinges with epoxy then slide the aileron into
position. Make sure the aileron is seated properly with minimal gap between
the wing and aileron and wipe away any excess glue with an alcohol soaked
rag. Pay careful attention to wipe any excess glue from the hinge knuckle. Set
the assembly aside to dry. Once dry the aileron movement may feel a bit stiff.
A drop of Acetone placed on the knuckle of each hinge will help to free the
aileron. Then apply a drop of Teflon or silicon lubricant to each hinge and
work it into the joint by moving the aileron back and forth multiple times.
Wipe away any excess lubricant with an alcohol soaked rag. Now is a good
time to seal the hinge line gap with Blenderm tape or Oracover (Ultracote) if
you desire to do so.

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5. Secure a 12 inch servo extension to the aileron servo lead and install your
aileron servo as shown with the output shaft oriented toward the leading edge
of the wing.
6. Assemble the aileron linkage as shown and secure to the aileron horn assembly
and servo arm with the provided 3mm bolts. Apply blue Loctite to all bolts!

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7. Repeat this process for the other wing, then inspect them both for taut covering
and any lifting seams that need attention with a hot iron or heat gun. Give a
good tug on the aileron to make sure all is secure, then clean the wings with a
soft cloth and Windex and set aside.Note, the wings mount to the fuselage
with nylon wing bolts.
Fuselage Assembly
8. Locate the carbon fiber landing gear and mounting bolt set in the hardware
bag. Insert each bolt into a washer, through the carbon gear and fuselage and
secure with a nylon insert locknut.

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9. Trial fit the landing gear cuffs to the carbon gear legs and mark their
location. Remove the cuffs and apply a bead of Silicon based Goop glue
completely around the gear leg as shown. Slide the cuffs into place and secure
with tape until dry.

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10. Locate the landing gear hardware pack with includes two axles, two locking
nuts, two large washers, two wheels, four wheel collars, two wheel pants and
four M3 bolts and blind nuts. Attach the axles to the landing gear with the
locking nuts and large washers.Install one wheel collar, then wheel, then a
second wheel collar. Test fit the wheel pant for proper wheel placement.
Attach both the inside and outside wheel collars to center the wheel in the
wheel pant. Now would be a good time to grind a flat spot in the axle to give
the outer wheel collar a better grip.

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11. Position wheel pants in place. Use the two holes in the landing gear as a guide
to drill two holes in wheel pants for attachment. Use M3 blind nuts and bolts
to attach as shown.

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12. Locate the tail wheel assembly. Now is a good time to remove all bolts and
fasteners in the assembly and apply blue Loctite to these fasteners. Locate the
three holes in the rear of the fuselage for the M3 bolts. Fasten the tail wheel
assembly as shown.

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13. Locate the rudder, rudder control horns and hardware. Prepare the rudder
control horns as previously done with aileron control horns. NOTE: IT IS
RECOMMENDED TO USE THE PULL-PULL RUDDER SERVO
LOCATION FOR THE 92” EDGE V2! This is for weight and balance
purposes. The rudder has two positions for the rudder control horns. Please
note in the following picture.

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14. Glue the control horns in the upper position with the same technique used for
aileron control horns. Hinge rudder the same as the ailerons.
15. Locate the slots for the pull-pull cable exit and open with a sharp Xacto knife
or soldering iron. Run the pull-pull cables through the fuselage. Note, the
wires should cross inside the fuselage. Mount the rudder servo as show. Using
the Extreme Flight 4 inch arm, tapped for M3. Assemble four ball links to the
pull-pull ends, screwing into the ball links 1/3 of the way. This will allow room
to tighten the cables when assembly is complete. Install one crimp sleeve on
cable before inserting cable into pull-pull end. Allow enough cable to go back
in crimp sleeve and a second loop around sleeve. See photos below for
reference. Once satisfied with the loops, crimp sleeve with pliers. Also
crimping the sleeves with a wire (side) cutters is good practice. Be sure not to
press too hard to cut the sleeve. It is easier to do the rudder servo side first.
Tape the rudder in the neutral position and finish pull-pull wires at the rudder.

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16. The firewall of the Edge has laser scribed locations for mounting the DA 70.
Drill at the correct location for your choice of power plant. If using an
alternative motor/engine simply download the mounting template from the
engine manufacturer's website and align with the centering marks on the
firewall and drill the appropriate holes. Mount the DA 70 using EF’s Blazing
Star DA 70 stand off.

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17. Throttle servo may be mounted under the motor box as shown.
18. If using stock mufflers, it is recommend to remove the tunnel cover for
additional airflow. Also open vents on the bottom of the fuselage.

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19. Mount mufflers, cut cowl as needed for mufflers. Install EF’s 17 or 24 oz.
Flowmaster fuel tank. Mount ignition on the top of the motor box as shown.
Complete the engine installation with your preferred components.
20. The Xpwr 60 Brushless Electric Outrunner from Extreme Flight is also an
excellent powerplant for the Edge, producing gobs of clean quiet power
rivaling that of the DA-70. We sell a set of Blazing Star XL standoffs that
make mounting the Xpwr 60 very easy. Below is a photo of the Xpwr 60
installed along with our recommended ESC, the Castle Creations HV160.
Make sure to use firmware version 4.22 for best results! The Xoar 24x12 PJN
is the ideal prop for this setup. There is a mounting option on the bottom of
the motor box for the HV160. This position provides needed airflow.

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21. When satisfied with motor or engine installation, mount the cowl using
supplied M3 hardware installed through holes in the F1 former into blind nuts
in the cowl. There is one additional cowl bolt on the bottom.
Horizontal Stabilizers
22. Prepare and install the elevator control horns as previously done with the
aileron control horns. Also install elevator hinges the same as the ailerons.
Note, there are shorten hinges at the inboard location of the elevator to allow
clearance of the stab tube and control horn. See picture below for reference.
Mount elevator servos inside stabilizers as shown. Mount the EF 2 inch servo
arm and complete elevator pushrod assembly. Be sure both elevator push rods
are equal length. The stabilizers mount to the fuselage with one carbon fiber
tube and two M3 bolts (per side).

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