AeroWorks 100cc Edge 540 ARF-QB User manual

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100cc Edge 540 ARF-QB
(Quick Build)
ASSEMBLY MANUAL
AEROWORKS
4903 Nome St– Denver, CO. 80239
www.aero-works.net

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TABLE OF CONTENTS
Page
Aeroworks Contact Information …………………………………………………………………………. 3
Introduction / Warranty…………………………………………………………………………. ………. 4
Kit Contents………………………………………………………………………………………………… 5
Items Needed To Complete ……………………………………………………………………………….. 8
Tightening and Re-shrinking The Covering ……………………………………………………………… 9
Ultracote™ Colors …………………………………………………………………………………………. 10
Checking Seams and Color Overlaps for Good Seal / Sealing Hinge Gaps ………..………………….. 11
Checking Hinges For Proper Throw………………………………………………………………………. 12
Wing Assembly………………………………………………………………….…………………………. 13
Stab and Elevator 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
Ignition Installation . …………………………..…………………………………………………………. 45
Fuel Tank Assembly and Installation …………………….……………………………………. ………. 48
Standard Muffler/Cowl Installation ……………………..……..………………………………. ………. 55
Canister Muffler/Cowl Installation ……………………………………………………………. ………. 59
Radio Installation …………………………………………………………………………………………. 63
Preflight Preparation ………………………………………………………………………...….. …….. .. 66
Decal installation ………………………………………………………………………………………… 68
Center of Gravity– CG Buddy……………………………………………………………………………. 72
Center of Gravity / Control Throws ……………………………………………………………. ……… 74
Control Deflection Table ………………………….………………………………………………………. 77
Preflight Check List ……………………………………………………………………………………… 78

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4903 Nome Street
Denver, CO 80239
Phone: [phone]
Fax: [phone]
Website: www.aero-works.net
E-mail: [email protected]
Thank you for choosing the Aeroworks 100cc Edge 540 ARF-QB. We put great effort
into making this plane the best model you will ever build and fly. We have provided you
with the highest quality kit and performance possible. We wish you great success in the
assembly and flying of your new Aeroworks 100cc Edge 540 ARF-QB.
!WARNING!
An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and property
damage. Fly only in open areas, and AMA (Academy of Model Aeronautics) approved
flying sites. Follow all instructions included with your plane, radio, and engine.
Aeroworks manufacturing guarantees this kit to be free from defects in both material
and workmanship 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. Further, Aeroworks reserves the right to
change or modify this limited warranty without notice.
In that Aeroworks has no control over the final assembly or materials used for final as-
sembly, No liability shall be assumed nor accepted for any damage resulting from the
use by the user of the final user-assembled product. By the act of using the user-
assembled product, the user accepts all resulting liability.
We, as the kit manufacturer, have provided you with a top quality, thoroughly tested kit
and instructions, but ultimately the quality and fly ability of your finished model
depends on how you build it; therefore, we cannot in any way guarantee the
performance of your completed model, and no representations are expressed or
implied as to the performance or safety of your completed model.

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INTRODUCTION
Your new 100cc Edge 540 ARF-QB is a highly aerobatic airplane. It is capable of both pre-
cision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state
of the art CAD design, LASER cut technology, and high quality included hardware. We
hope you enjoy building and flying your 100cc Edge 540 ARF-QB.
Great care has been taken in both the design and manufacturing of the 100cc Edge 540 ARF
QB to allow for the strongest and lightest construction possible. Only the highest quality ma-
terials from the covering, paint, wood and hardware have been used in the construction of
this model.
The 100cc Edge 540 ARF-QB has been individually hand built, covered and painted by
trained and experienced craftsmen with over 25 years of manufacturing experience. Using
CAD design, laser cut technology and jig-built assures accuracy in all stages of production.
The 100cc Edge 540 ARF-QB is designed for gas engines in the 100cc category. The DA-
100cc engine is shown in the assembly instructions. The aircraft was tested with the DA-
100cc and has outstanding performance. The final choice of engine is left up to the builder.
A computer radio is recommended to allow the pilot to take advantage of the full capabilities
of this aerobatic aircraft.
IMPORTANT Please read through this assembly manual carefully, before starting the as-
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 assembly. Inspect all parts and hardware prior to any assembly,
failure to do so could void any warranty coverage.
INTENDED USE
This plane should not be regarded as a toy. This is an aerobatic plane and is recommended for pilots
who are beyond the trainer-stage and are comfortable with flying an aerobatic sport plane.
READ! LIMITED WARRANTY READ!
It is important to notify Aeroworks of any damage or problems with the model within 30
days of receiving your airplane to be covered under warranty. If you wish to return this air-
craft for any reason a 15% restock fee will be charged to the customer. In addition the cus-
tomer is responsible for all return shipping cost and all prior shipping cost will not be re-
funded. Parts will be fixed or replaced once the original item is returned at the owner’s ex-
pense. If you have any problems or questions, please contact Aeroworks.
Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the
construction or use of this aircraft, and therefore, will not be accountable for any property
damage, bodily injury or death caused by this aircraft.
Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the
construction or use of this aircraft, and therefore,
The purchaser/operator accepts all responsibility of any and all structural or
mechanical failures.

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KIT CONTENTS
100cc Edge 540 ARF-QB
BASIC AIRCRAFT PARTS:
Fuselage with pre-installed vertical fin – covered, fire-
wall fuel-proofed, pre-drilled three holes for the tail
wheel assembly::
(4) 8-32 blind nuts installed for main landing gear
(6) 4-40 blind nuts installed for the mounting of
the stab(4),Cowling(2)
(1) Engine box top hatch cover with AW logo in
stalled by (4) T2.6x8mm PWA screws
(1) Engine box bottom hatch cover with AW logo
installed by (4) T2.6x8mm PWA screws
(1) Bottom Canister Hatch installed by (4)4-40
blind nuts, (4)4-40x10mm hex style bolts and (4)
3mm flat washers
(1)Hatch cover for the landing gear installed by
(2) T2.6x14mm PWA screws
Canopy base—painted, with (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 split lock washers for the mounting of
the canopy
3.5(o.d.) x1000mm Antenna tube installed
(2) 3.5(o.d.) x100mm pull-pull exit tube installed
(2) Elevator servo string installed
Left Wing with Aileron – covered: Pre-drilled for the
mounting of the control horns
8-32 blind nuts installed for the wing mounting.
(2) located pins installed pre-drilled hole for cot-
ter pin
(8) pin point hinges glued
(2) Aileron servo string installed
Right Wing with Aileron – covered: Pre-drilled for the
mounting of the control horns
(2) 8-32 blind nuts installed for the wing mount-
ing.
(2) located pins glued pre-drilled hole for cotter
pin
(8) pin point hinges installed
(2) Aileron servo string installed

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Horizontal Stabilizer with elevator assembly with (12)
pin point hinges (glued)---covered
Elevators Pre-drilled for the mounting of the con-
trol horns
Rudder with (7) pin point hinges (not glued) – covered
Rudder Pre-drilled for the mounting of the con-
trol horns
SUB ASSEMBLIES:
#1:
(1) Fiberglass Cowling w/ inside ring glued—painted
with (2) screws holes at bottom and (2) 6-32 blind
nuts installed
(2) 4-40x16mm hex style bolts for mounting cowling
(2) #6 bonded washers for mounting cowling
(2) 3mm split lock washers for mounting cowling.
(2)6-32x16mm hex head bolts for mounting cowling
(2) #6 bonded washers for mounting cowling
#2:
(1) 5mm 7075Aluminum Main Landing Gear --
painted
(2) 5x48mm AL Axle Bolts
(2) M8 lock nuts
(4) 5mm i.d. Wheel Collars with set-screws
(2) 100mm Dia. Main Wheels (Lite Type)
(4) 4-40x14mm hex style bolts for mounting wheel
pants
(4) 3mm flat washer for mounting wheel pants
(4) 3mm split ring lock washer for mounting wheel
pants
(4) 8-32x20mm hex head bolts for mounting main
landing gear
(4) 4mm flat washers for mounting main landing
gear
(4) 4mm split ring lock washers for mounting main
landing gear.
#3:
(2)Wheel Pants—1 Left and 1 Right---Painted
(4) 4-40 blind nuts installed on the wheel pants, 2 per
side.
#4:
(1) AL Tail Wheel Assembly with Rubber wheel –
LARGE
#5:
(1) 40mm o.d. Aluminum Tube for wing joint—
Anodized Black
(2) 12.5mm o.d. Aluminum Tube for stab joint – one
front and one rear, Anodized Black
(4) 8-32x25mm Hex head bots for wing mounting
(4) #8 bonded washer for wing mounting
(4) 4mm split ring lock washers for wing mounting
(4) 4-40x16mm Hex style head bolts for 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 for ailerons
(2) 4-40 2-1/2” Left hand and Right hand threaded
pushrods with nuts and carbon tubes for elevators
(1) Wrench for the left hand and right hand
threaded pushrod
(2) 4-40x300mm Threaded pushrods
(2) 4-40 solder coupler with nuts
(2) 4-40 Metal clevises
(10) brass spacers – 4 for ailerons; 2 for elevators; 2
for throttle; 2 for choke
(16) 4-40 Ball Link – 8 for ailerons; 4 for elevators; 2
for throttle; 2 for choke
(16) 4-40x16mm hex style bolts
(16) 4-40 lock nuts
(16) Φ3mm flat washers
#7:
(2) 1x1300mm plastic coated pull-pull steel cable.
(4) 4-40 Metal R/C links with nuts
(4) 3.5x5mm brass pull-pull swaging tubes
(8) AL double control horns
(36) T2.6x16mm Phillips head mounting screws
(12) T2.6x12mm Phillips head mounting screws
(2) 4-40x36mm left hand and right hand threaded
pushrod for connecting rudder servo
(4) 4-40 Ball Links for connecting rudder servo
(4) 4-40x16mm hex head bolts for connecting rudder
servo
(4) 4-40x20mm hex head bolts for connecting rudder
servo
(4) Brass Spacers for connecting rudder servo
(4) 3mm flat washers for connecting rudder servo
(4) 4-40 Ball Links – Rudder
(4) 4-40 x16mm hex style bolts
(6) 4-40 lock nuts
(2) Brass Spacers for rudder
(2)Φ3 flat washers
#8:
(1) 1000cc Gas Fuel Tank Assembly
(1) 750cc Gas Fuel Tank Assembly
(1) 4ft. large gas fuel line
(4) Brass Barbs for fuel line
(2) Fuel filler Dot – 1 male and 1 female
#9:
(2)Throttle and Choke servo mounting trays
(1) Canister mounting bracket with Silicon Tubes
(3) Engine Mounting Template (DA100;3W100 and
Universal)
(2) 8x8x300mm Sponge for the receiver and battery
(1) 6x70x160mm Foam for the Fuel Tank

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(1)6x100x160mm Foam for the Fuel Tank
(8) 8x450mm Nylon Ties for the fuel tank mounting
(10) 3x150mm Small Nylon Ties for the fuel line
(6) 356x12.5mm Velcro
(1) Card Stock (8”x11”) for making the template for
cutting of cowling
(1) pre cut template for cutting the bottom of the cowl
(1) Paper Degree Meter for the Rudder
(1) Φ12mm Aluminum Insert
(6) Rubber Grommets – each forΦ6mm,
Φ8mmΦ10mm – Fuel line and wire guide
#10:
(24) 6.35mm Aluminum Engine Stand offs.
#11:
(1) C.G. Buddy
#12:
(1) 300x300mm White Covering
(1) 300x300mm Cub Yellow Covering
(1) 300x300mm Pearl Charcoal Covering
OR(1) 300x300mm White Covering
(1) 300x300mm Orange Covering
(1) 300x300mm Pearl Charcoal Covering
(2) 20x1800mm transparent covering
#13:
(1) Custom throw meter
#14:
(1) Manual CD
#15:
(1) Vinyl Decal Set

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Hardware:
ITEMS NEEDED TO COMPLETE
• 100cc gas engine with ignition, mufflers or
headers, with canisters or pipes, and all engine
mounting bolts, lock nuts, and washers.
• 4” Spinner and propeller of your choice
• 4 x aileron servos (min. 180 in./oz. Digital,
Metal Gear)
• 2 x rudder servos (min. 180 in./oz each or 300
in./oz. total torque, Digital, Metal Gear)
• 2 x elevator servos (min. 180 in./oz. Digital,
Metal Gear)
• 1 x throttle servo (fast / reliable)
• 1 x choke servo (fast / reliable) (Optional)
• Servo extensions - Heavy Duty - (22 gauge min)
3 x 11” Y harness, 2 x 6,” 2 x 12”, 2 x 24”, 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 cutting disc and sanding drum tool
• Electric drill and selection of bits
• Flat head screwdriver
• Hobby heat gun
• Hobby iron with protective sock
• Masking tape
• Modeling knife
• Needle nose pliers or crimping tool
• Paper towels
• Pen, pencil or felt tipped marker
• Phillips screwdriver
• Ruler and tape measure
• Scissors
• T pins
• Waxed paper
• Wire Cutters
Adhesives:
• 15-30 Minute epoxy
• Blue Loctite (Thread Locker)
• Epoxy mixing cups, sticks, brushes
• CA kicker (optional)
• Thick and Thin CA
• Rubbing alcohol
• Wipes
!WARRING!
Some rubbing alcohols
may attack painted parts.

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1. Open your kit slowly and take care not to dam-
age any parts of the kit. Remove all parts from
their plastic protective covers for inspection.
Before doing any assembly or installation of any
decals it is very important to re-shrink or re-
tighten the already applied covering. Due to the
shipping process, heat and humidity changes
from different climates, the covering may be-
come lose and wrinkle in the sun. If you take the
time to re-tighten the covering, you will be re-
warded with a long lasting beautifully covered
model.
TIGHTENINGAND RE-SHRINKING THE COVERING
2. Using your covering iron with a soft sock, gently
apply pressure and 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
covering to the wood. This is especially im-
portant at the leading edges of the wings and
stabs.
3. If bubbles persist, use a small pin to punch holes
in the bubble to relieve trapped air and reheat.
4. Use your heat gun with extreme caution. Take
care not to apply too much heat to one area for
long periods of time. This may cause the trim
colors to over shrink and pull away leaving un-
sightly gaps on the color lines. The trim stripes
are especially vulnerable to over heating and
over shrinking.
Tightening and re-shrinking the covering is now
complete. However, this is a never ending
process and should be checked after each
flying session.

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1. Your model is covered 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 Charcoal #846
White #870

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1. Go over all seams and color overlaps with your
sealing iron.
Note: Even if your models covering has no wrin-
kles out of the box it is still very important to
go over all seams and overlaps to make certain
they are sealed securely. This is especially
important at the leading edges of the wings and
stabs. We recommend checking the covering
after each flying session.
CHECKING SEAMS AND COLOR OVERLAPS FOR GOOD SEAL
SEALING HINGE GAPS
2. Use covering iron to ensure all edges, seams,
and color overlaps are securely sealed.
3. Sealing hinge gaps. This is an optional step
but is recommended.
Cut strips of the supplied clear covering to fit
the hinge 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. This must be removed
prior to applying heat and to the surface.
IMPORTANT:
It is the responsibility of the purchaser /
operator to check the covering seams and
overlaps for security and a good seal.
Aeroworks is not responsible for failure of
covering seams or overlaps during flight.
Note: If covering continues to lift apply a small
amount of thin CA underneath the covering.
Then using a clean rag apply pressure to secure.
One of the most important tools in your
flight box is a roll of clear tape. This can be
used at the field for fast and easy repairs of
the covering. Then once you have finished
flying the covering can be permanently
repaired.

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CHECKING HINGES FOR PROPER THROW
2. Evenly heat each hinge along the entire length of
the wing. This will allow the hinge glue to soften
and the hinge to move into it proper position.
Hold the surface at full deflection until 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 will throw to their full deflect-
tion.
IMPORTANT
1. If control surfaces will not throw to full deflec-
tion it may be necessary using a heat gun to
apply heat to the knuckle of each hinge. This
will allow the hinges to move freely.

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Aileron Servo Installation
1. The ailerons have been pre-hinged and glued to
the wing panels and are ready for flight. No
other steps are necessary for hinging. Clear
Covering is supplied for sealing the hinge gaps if
desired. However, due to the precisely aligned
and minimal hinge gap this step is optional.
Gather the following items for each wing
panel:
• (2) Aileron Servos 172 in./oz torque ea re-
quired
• (1) 11” Y harnesses: Optional See below
• (1) 24” servo extension
As shown 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 with mixing capabilities it
will not be necessary to use a Y harness.
WINGASSEMBLY
2. Layout the servos, extensions and Y harness on
the wing to test fit the installation and ensure
servo leads are the correct length.
Minimum recommended servo:
172 in. oz. / Metal Geared / Digital
3. Attach the 6” extension to the servo lead and
secure with Aeroworks Safety Clip. Ensure the
connectors will not come apart from vibration or
light tension.
Safety Clips
Available
from
Aeroworks

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5. Pull the servo lead through the root end of the
wing.
6. Attach the Y harness to the inboard servo lead
and secure with an Aeroworks safety clip. En-
sure the connectors will not come apart from
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 string from
the servo well and tie the pull string to the servo
lead as shown.
4. Remove the balsa stick with the pull string from
the servo well and tie the pull string to the servo
lead as shown.

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9. Plug the male ends of the 24”extension into
the female ends of the Y harness. Next plug
the male end of this Y harness into the female
end of the 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 well with the output shaft
toward the leading edge of the wing. Use a
1/16 bit to drill servo mounting holes.
8. Pull Y harness through root end of wing.

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13. Repeat mounting steps for other servo so that
aileron servos are mounted in bottom of wing
as shown.
Note: Servo output shaft should face towards the
wing leading edge. Servo arms should point
towards the wing tip.
12. Install servo with servo mounting screws.
2. Assemble two pushrod and control horn
assemblies as shown. The ball link goes
between the left and right sides of the control horn
sides and is secured with a nylon lock nut.
IMPORTANT: The ball link for the root end
control horn goes in the bottom hole of the horn.
The ball link for the tip end horn goes 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 system to as-
sure your servos will not bind or fight against
each other.
Improperly installed servo linkages can cause ser-
vos to strip and ailerons to flutter. Aileron flutter
can and will destroy your model instantly!
Tip end
Middle hole
Root end
Bottom hole
Aileron Control Linkage Installation
1. Gather the aileron control linkage parts as shown
below. There are (2) 4-40 pushrods, (4) 4-40 ball
link assemblies, (2) Flat washers (2) brass spacers,
(2) left and (2) right side control horns, (1) Adjust-
ment wrench (4) carbon reinforcement sleeves and
(12) wood screws for each wing panel.

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4. Align the control horns over the factory drilled
holes.
Note: Control horns have been set at a slight
offset to allow for maximum torque at full
deflection
6. Align the left and right 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 time.
Remember to work quickly
3. Correct installation of ball link, flat washer and
brass spacer to servo arm shown below.
Note: Flat washer prevents ball link from
coming off brass ball.

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8. Plug the servos into the receiver and turn on.
Ensure servos are centered and the servo arms
are parallel to the aileron hinge line. Adjust
the length of the pushrods so that the aileron is
at the neutral position when the servo 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
available today to achieve best results. This
will help keep servos from binding and
causing possible aileron flutter.
7. Install servo arm to pushrod as shown below. 9. Finished wing panel shown below, repeat steps
for remaining wing panel.

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Elevator Servo Installation
1. The elevators have been pre-hinged and glued to
the stabs and are ready for flight. No other steps
are necessary for hinging. Clear covering has
been provided for sealing of the hinge gaps if
desired.
Gather the stab and elevator, one elevator
servo, and one 48” servo extension.
Note: 48” servo extension will be used to
connect servos to receiver during a later
step.
STAB AND ELEVATOR 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 mounting holes. Use a
1/16 bit to drill servo mounting holes.
4. Install servo with servo mounting screws.
1. Gather the elevator control linkage parts as
shown below. There are (1) 4-40 pushrods, (2)
4-40 ball link assemblies, (1) Flat washers (1)
brass spacer, (1) left and (1) right side control
horns, (1) Adjustment wrench (2) carbon rein-
forcement sleeves and (6) wood screws for each
elevator half.
Elevator Control Linkage Installation

20
4. Align the control horns over the factory drilled
holes.
Note: Control horns have been set at a slight
offset to allow for maximum torque at full
deflection
5. 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.
2. Assemble the pushrod and control horn assem-
bly as shown. The ball link goes between the
left and right sides of the control horn sides and
is secured with a nylon lock nut.
3. Correct installation of ball link, flat washer and
brass spacer to servo arm shown below.
Note: Flat washer prevents ball link from
coming off brass ball.