AeroWorks 31% EDGE 540T ARF User manual

AEROWORKS
31% EDGE 540T ARF
ASSEMBLY MANUAL

Required but not included Aircraft Specifications:
4 channel radio Wing Span 92”
Engine 3.2 to 4.2 c.c. Wing Area 1380 Sq. in.
Fuel Tank 24 ounce or larger Length 80”
Spinner 3 ½” Weight 16 to 18 pounds
Congratulations! You have just become the owner of one of the highest quality ARF’s in both
material and workmanship in the industry. Aeroworks uses only hand select balsa wood and the
highest quality of light ply and hardwood available. All fiberglass parts are hand crafted and
inspected for imperfections. We have designed the Egde 540T to be lightweight, yet strong
enough to handle the aerobatic forces expected from a high performance airplane.
Thank you for purchasing the Egde 540T ARF. We wish you great success in both the assembly
and flying of your fully aerobatic airplane. If you have any questions or comments feel free to
call.
Aeroworks [phone]
[phone] Fax
Or write to: Aeroworks
401 Laredo Unit “D”
Aurora, Co. 80011
www.aero-works.net
Before starting the assembly process of your new Egde 540T ARF, Please read through the
assembly manual carefully, and inspect all parts and any hardware for imperfections or damage.
It is important to notify Aeroworks of any damage or problems with the model immediately. If
you wish to return this aircraft for any reason a 15% restock fee will be charged to the customer.
In addition the customer is responsible for all return shipping cost.
Aeroworks cannot insure the skill of the modeler in the construction or use of this aircraft.
Therefore, will not be accountable for any property damage, bodily injury or death caused by this
aircraft.
The purchaser also accepts all responsibility of any and all structural or
mechanical failures.
1

EQUIPMENT REQUIREMENTS
AILERONS: Servo’s: 70 Ounce minimum, two per wing, you may select to use only one
servo per wing panel. If you do, you will need to place it in the servo slot toward the root end of
the wing and must use a 100-ounce minimum servo. Digital and metal-geared servos are highly
recommended. If you select the two-servo option, Digital and metal geared servos are not
required.
ELEVATORS: Servo’s: 70 Ounce minimum one per stab. Digital and metal geared servos
are not required. However are recommended. Especially if you plan on doing 3-D style
maneuvers.
RUDDER: Servo’s: 70 ounce minimum, two required, push-pull system located in rear of
fuselage. Digital and metal-geared servos are not required, however are recommended. You will
need to use a pull-pull system, located in the radio compartment, if you are using a lighter
engine, 5 pounds or less. If you do select to use a pull-pull system you can use one high torque
servo 130 ounce or gang two lower torque 65-ounce servos together. The decision of using a
push-pull system versus a pull-pull system will depend on aircraft balance. Try to use the rudder
servos to help achieve the correct C.G. location.
pull -pull system located in the radio compartment. Digital and metal geared servos are not
required, however are recommended
THROTTLE: A high torque servo is not necessary, 48 ounce minimum. However, a reliable
and fast servo is recommended.
RECEIVER BATTERIES: We recommend you use a 1700 MA 6 volt pack.
SWITCHES AND WIRING: It is important to use heavy gage wire ( 22 gauge ) for all
switches, batteries, and extensions.
FUEL TANK AND LINE: Use a 24 oz. fuel tank with large diameter size fuel line. Gas will
cause fuel lines to swell and come off brass fuel tubing. Be certain to always tie down your fuel
lines with clips or wire. It is also recommended to solder a barb onto the brass tubing for extra
security.
HARDWARE: It is recommended that you use the optional hardware package offered through
Aeroworks. If you do not use the Aeroworks package, we recommend that you use high quality
hardware designed for the larger planes.
RECEIVER: The use of a PCM receiver is recommended.
2

STEP A
TIGHTENING AND RE-SHRINKING THE COVERING
Open your kit slowly and take care not to damage 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 Ultracote covering. Due to the shipping process, heat and humidity
changes from different climates, the covering may become lose and wrinkle in the sun. If you
take the time to re-tighten the covering, you will be rewarded with a long lasting beautifully
covered model.
Using you’re covering iron or heat gun 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. If bubbles
persist, using a small pin, punch holes in the bubble to relieve trapped air and reheat. We do not
recommend using a heat gun on any of the foam surfaces. Too much heat on one area may cause
the foam to melt underneath the wood.
After you have tightened up the covering, it is time to start the assembly of your Edge.
STEP B
FUSELAGE ASSEMBLY
With sharp xacto knife cut covering away from wing and stab tube holes. Cut covering away
from stab and wing anti-rotation holes. Cut covering away from aileron servo wire access slot in
fuse and rudder servo cut outs in the rear of the fuselage. If you are using a lightweight engine
you may select to put your rudder servos in the radio compartment using a pull-pull system. It is
recommended you check your C.G. prior to installing rudder servos.
STEP C
WING ASSEMBLY
1) Locate the pre cut hinge slots in the wing and aileron. The model comes with CA style
hinges pre installed, but not glued into the control surfaces. If you wish to use the CA hinges
3

we recommend adding additional hinges to each surface and use thin foam safe CA when
gluing in hinges. We have used the CA type hinges with no problems. However, we highly
encourage the builder to use the nylon pinned style hinge, such as the Klett ¼ scale hinge.
You will have to enlarge the hinge slot to accommodate the nylon hinge. Check surfaces for
alignment and glue hinges into the control surfaces. We recommend using slow set epoxy or
hinge glue. Be certain to give yourself plenty of aileron throw. Recommended throw is 35
degrees minimum up and down. We also recommend using Ultracote to seal all control
surfaces.
2) Locate servo locations on bottom side of wings and remove covering. (Two per aileron). If
one servo option is desired, be certain to use a high quality 100 ounce minimum servo,
and use the servo slot closest to the fuselage. Attach servo extension leads to your servos, it
will be necessary to “Y” the two servos together and run one wing panel into the aileron port
of your receiver and the other panel into an auxiliary port of your receiver, designated by the
manufacturer of your radio. Tie the pre-installed nylon string to your servos and pull the
servo wire through the wing. Install servos into wings. It is important to secure the servo
connectors with tape, wire or after market clip to be certain the leads do not disconnect.
Above
p
hotos are of a different model but use the same servo installation
p
rocedures
3) Locate hardwood blocks pre installed in the ailerons. Drill and tap the control horn locations
for an 8/32 bolt. Install the control horns so your linkage will be 90 degrees to the servo arm.
We recommend using the Nelson Hobby control horn assembly #RCL70.
8-32
TAP
CONTROL
HORN
Drill 90
degree to
servo arm
4) When setting up the servo linkage, we recommend using 4-40 rod with a silver solder clevis.
It is very important to have all control linkages 90 degrees to the control surface and servo
arm. If more throw is required then the silver solder clevis will enable, then we recommend
using a du-bro swivel ball link at the servo arm for more movement.
4

SILVER SOLDER
CLEVIS SERVO ARM AND CONTROL HORN AT 90 DEGREE
5) It is best to have the linkage as far in on the servo arm as possible and as far away from the
control surface as possible. If you are setting up the plane for 3D style flying. We
recommend using larger after market servo arms. It is important not to be closer then 1” from
the control surface with your control horn. If you get to close to the control surface you may
develop flutter. Special note: Remember to center all servos prior to connecting linkages to
servo. This will eliminate any binding when the radio is turned on.
6) Locate the hardwood dowel for the wing retainer bolt, located on the bottom of each wing.
Pre drill a 1/8” hole into the center of the dowel for the wing retainer bolt.
7) Slide aluminum tube through fuse and center in the fuse. Secure tube in fuse so tube cannot
move. A hose clamp works well for this. Slide both wing panels onto tube and push tight
against the fuse.
8) Drill and tap dowel and aluminum tube for 6-32 bolt.
Epoxy
hardwood in
wing tube
drill and tap
for 6-32 bolt
Wing
retainer
dowel
location
9) Leaving the aluminum tube in one wing panel, with wing retainer bolt secured, at all times,
will enable you to always find the tapped hole for the bolt. Remove one wing panel and
centered on the location of the retainer bolt, epoxy hardwood into the end of the aluminum
tube. Drill and tap hardwood for 6-32 bolt. Repeat for other wing, remembering to keep tube
in one wing at all times. It will be necessary to round the top of the wooden block to fit inside
contour of aluminum tube.
5

STEP D
STAB AND ELEVATOR ASSEMBLY
1) Locate the pre cut hinge slots in the stab and elevator. The model comes with CA style
hinges pre installed, but not glued into the control surfaces. If you wish to use the CA hinges
we recommend adding hinges to each surface and use thin foam safe CA when gluing in
hinges. We have used the CA type hinges with no problems, however we highly encourage
the builder to use the nylon pinned style hinge, such as the Klett ¼ scale. Check surfaces for
alignment and glue hinges into the control surfaces. We recommend using slow set epoxy or
hinge glue. Be certain to give yourself plenty of elevator throw. Recommended throw is 45
degrees minimum up and down. We recommend sealing all surfaces with Ultracote.
2) Locate servo location on bottom side of stabs and cut away covering. (One per stab) Using
the pre installed nylon servo wire attachment string, pull servo leads through stab. You want
to have the male end of the servo extension hanging out the stab and the female end hanging
out from the fuse. This will enable you to remove the stabs easily when necessary. It works
best to run one elevator servo extension into the elevator port of the receiver and the other
into an Aux port of the receiver designated by your radio manufacture. If you do not have a
radio capable of splitting the elevators into two different channels, it is possible to reverse
one servo and use the same port or channel in the receiver. There are after market servo
reverses that work well. Install servo into stabs. It is important to secure the servo
connectors with tape, wire or after market clip to be certain the leads do not disconnect.
3) Locate hardwood blocks pre installed in the elevators. Drill and tap block for control horn
locations for a 8/32 bolt. Install the control horns so your linkage will be 90 degrees to the
servo arm. We recommend using the Nelson control horn assembly #RCL70.
Seal all hinge gaps
with Ultracote
covering
DO NOT counter
sink bolt head.
Use flush mount
bolt
4) When setting up the servo linkage we recommend using 4-40 rod with a silver solder clevis.
It is very important to have all control linkages 90 degrees to the control surface and servo
arm. If more throw is required then the silver solder clevis will enable, then we recommend
using a du-bro swivel ball link at the servo arm for more movement.
6

5) It is best to have the linkage as far in on the servo arm as possible and as far away from the
control surface as possible. If you are setting up the plane for 3D style flying. We
recommend using larger after market servo arms. It is important not to be closer then 1” from
the control surface with your control horn. If you get to close to the control surface you may
develop flutter. Special note: Remember to center all servos prior to connecting linkages to
servo. This will eliminate any binding when the radio is turned on.
6) Locate the hardwood dowel for the 4-40 stab retainer bolt, located on the bottom side of each
stab. Pre drill a small hole into the center of the dowel for the stab retainer bolt.
7) Slide aluminum tube through fuse and center tube in fuse. Secure one end of tube in fuse so
tube cannot move. Slide one stab panel onto tube and push tight against fuse.
STAB
RETAINER
DOWEL
LOCATION MEASURE
EQUAL
DISTANCE
TAP FOR
4-40
BOLT
8) Drill and tap dowel and aluminum tube for 4-40 bolt. Secure stab to tube with 4-40 bolt, then
slide other stab onto tube and repeat retainer bolt installation. Be certain both stabs are tight
against fuse.
9) Leaving the aluminum tube in one stab panel, with stab retainer bolt secured, at all times will
enable you to always find the tapped hole for the bolt. Remove one stab panel and at the
location of the retainer bolt, epoxy hardwood into the end of the aluminum tube. Drill and
tap hardwood for 4-40 bolt. Repeat for other stab, remembering to keep tube in one stab at
all times.
STEP E
ENGINE BOX ASSEMBLY
1) Cut 1/8” ply engine box sides to correct length to accommodate your engine size. Be sure to
leave room for soft mounts if used. Soft mounting is not required. An easy way to
determine the correct length of box sides is to slide the cowl over Former F1 approximately
¾” to 1”. Measure from front of former F1 to front of the cowl. Now measure the length of
your engine. Subtract the engine length from your first measurement. This should be the
required length for your engine box sides. It is always a good idea to cut the engine box sides
slightly shorter then needed, approximately ½”. This will allow you to make adjustments by
adding spacers between firewall and engine. Adding a spacer will also allow for the rear
cylinder to be spaced away from the firewall to allow for better cooling. *Be certain to
check sides, one is longer then the other, this will give you the correct amount of right
thrust.
7

Pictures are of
different model
b
ut procedure is
the same
Measure From F1 to end of cowl to get correct box length
2) Slide engine box sides through former F1, slide notch of engine box sides into former F2.
Square sides to former F1. Using epoxy, glue sides to F1, F2 and fuse floor.
3) Epoxy 3/8” ply firewall to the inside of the engine box sides and flush with the bottom of
sides.
4) Cut 1/8” lite ply engine box floor to correct length. The floor should rest on bottom of sides
and firewall and butt up next to former F1.
5) Epoxy engine box floor to the bottom of sides, firewall, and front of former F1. Be certain to
square all parts to former F1.
6) Use 3/8” balsa tri-stock reinforcement at all glue joints. Behind firewall reinforce glue joint
with 3/8” spruce tri stock.
Engine shown is Zenoah G-62 with magneto.
8

STEP F
LANDING GEAR
1) Drill or tap axle hole in gear to fit your axle. We recommend 3/16” dia. Axle.
2) Install axles using thread lock or lock nut.
3) Draw a centerline, front to back, down both aluminum landing gear and ply mounting plate.
4) Align center marks.
The gear provided will
use four bolts
5) With gear centered on center line and 2 1/2” back from Former F1, drill four equally spaced
holes through gear and mounting plate, two front and two back, to accommodate
10-32 bolts.
Use 10/32 bolts and blind nuts to attach gear to block. Special note: Use thread lock on all
Gear bolts.
STEP H
FIN AND RUDDER ASSEMBLY
1) Locate the hardwood block pre installed in the rudder for the control horn. Drill and tap for
8-32 all thread. Install all thread into rudder and secure with flat washer and nut on each side.
You should have approximately 1” of bolt on each side of the rudder for the mounting of the
control horns. Use thread lock to secure.
Pictures are
of different
model but
procedure is
the same
2) Trail fit fin to fuse. Remove fin. Apply epoxy to all surfaces to be glued. Slide fin into the
fuse. Use tape to hold in place while assembly dries. (NOTE) Remove covering from all
glue areas and make sure the fin is glued to the rear of the fuse.
Remove
covering
from glue
areas
Epoxy fin
to fuselage
9

3) Locate pre cut hinge locations and glue hinges into fin and rudder. We recommend sealing all
control surfaces with Ultracote.
STEP I
CANOPY/HATCH INSTALLATION
1) Using scribe lines as reference, cut out canopy.
2) Trial fit canopy to hatch cover. Do all painting/prep work, dash panels and pilot installation
prior to gluing canopy. (NOTE) We recommend you remove the covering from the cockpit
floor location. We use an automotive trunk spatter spray paint (Grey or White) and paint the
floor location to complete a finished look.
3) Glue canopy to hatch cover. We use 3M stripping tape to finish out the canopy.
STEP J
COWL INSTALLATION
It is first recommended to install engine per manufactures recommendations.
Engine thrust line is 7/8” down from top of fuse box sides. 2 to 3 degrees of right thrust and 0
degrees of down thrust. It will be necessary to offset the engine to the left (pilot view) 3/8” to
compensate for right thrust. This will allow the center of the engine to exit at the center of the
cowl.
1) Fit cowl to fuse, cutting out where needed to accommodate engine. Remember to fit cowl
over fuse ¾” to 1”.
2) When fitting cowl to fuse. Use a 3 ½” spinner to ensure proper alignment with spinner plate
of cowl.
3) When satisfied with fit drill two 1/8” holes on each side of cowl and through fuse sides.
Approximately ¼” from rear of cowl.
4) Use 4-40 bolts and blind nuts to attach cowl to fuse.
NOTE: We recommend using metal/rubber washer to secure bolt.
Metal
washer
with
rubber
backing
10

5) Due to shipping and packaging, you may have a fine haze on the beautifully painted cowl. If
you do, using a fine rubbing or polishing compound will eliminate the haze effortlessly. You
can find this product at any automotive store.
STEP K
INSTALLING WHEEL PANTS
1) Make a notch in the wheel pant and lite-ply mounting plate with a Dermal drum sander.
Make the notch deep enough to let the wheel pant slide over the axle to the desired height.
2) Align the wheel pant to the gear and with 1/8” drill bit, drill two equally spaced holes through
gear and wheel pant. Mount wheel pants to gear with 4/40 bolts and blind nuts.
STEP L
CONTROL SURFACCE THROW
1) Elevator High rate 20 degrees up and down
Low rate 12 degrees up and down
3-D rate 40 degrees up and down
2) Rudder High rate 60% deflection
Low rate 30% deflection
3-D rate Full deflection
3) Aileron High rate 24 degrees up 24 degrees down
Low rate 18 degrees up 18 degrees down
3-D rate 35 degrees up 35 degrees down
The throws given are to be considered only a starting point. Adjust the throws to accommodate
your style of flying.
11

STEP M
BALANCING (C.G.) 2" IN FRONT OF WING TUBE or 3 3/4” BACK
FROM THE LEADING EDGE OF THE WING.
1) Balance the Edge 540T with fuel tank empty otherwise ready to fly.
2) With the wings and stabs on the plane, and the hatch cover removed. Using your fingers pick
up the model by the fuse sides at the proper C.G. location. The model should balance at this point.
This is a starting point for the C.G. and can be adjusted forward or aft depending on your flying
desires.
Measure
from front
of wing
tube
2”
STEP N
FLYING
We believe the Edge 540T will be one of the finest flying airplanes you will ever fly. The 540T has no bad
habits and very slow speed stall characteristics.
Inverted flight is nearly hands off and knife edge flight takes little or no mixing to remain straight and true.
Remember the Edge is a large aircraft and picks up speed quickly when coming out of split S type
maneuvers or when needing straight downward. (Always throttle back).
If you have followed the assembly manual instructions and have balance your Edge properly, you will be
rewarded with a highly aerobatic, stable and predictable flying airplane.
12

Mount ignition (if used) in engine box.
Protect with foam and screw or nylon tie
down.
Always protect
wires Secure battery with
hooks and rubber
bands
Optional rudder
servo location.
You must use a
pull-
p
ull system i
f
your engine
weighs less then 5
pounds
Typical radio and tank installation
Zenoah G-62 shown, mounted with ¼ - 20 bolts for stand offs, and a Abell pitts style muffler.
Strip aileron horn
Elevator and rudder servo installation Tail wheel installation
Push-Pull
system
shown
13

ACCESSORIES FOR YOUR EDGE 540T
DECAL SET AVAILABLE $125.00
AEROWORKS REALISTIC PILOTS AVAIALBLE $39.95
Available in: Red, Yellow, Blue or Black Shirt color and Head Set or Ball cap version.
DASH PANELS AVAILABLE $39.95
FRONT
REA
R
WING BAGSAVAILABLE $115.00 SATB BAGS AVAILABLE $49.00
WING BAG STAB BAG

HARDWARE PACKAGE AVAILABLE $115.00
FUSELAGE
4 4/40 x ½ SOCKET HEAD CAP DU571 COWL MOUNT
4 #4 FLAT WASHER DU 323 COWL MOUNT
4 4/40 BLIND NUTS DU 135 COWL MOUNT
4 10/32 X ¾ SOCKET HEAD CAP DU 580 LANDING GEAR
4 10/32 BLIND NUTS DU 584 LANDING GEAR
4 #10 FLAT WASHER DU 586 LANDING GEAR
4 4/40 X ½ SOCKET HEAD CAP DU 571 WHEEL PANTS
4 4/40 BLIND NUTS DU 135 WHEEL PANTS
4 #4 FLAT WASHER DU 323 WHEEL PANTS
2 5/32 AXLE SHAFTS DU 248 MAIN WHEELS
4 5/32 WHEEL COLLARS DU140 MAIN WHEELS
2 3” DIAMETER WHEELS DU 300L MAIN WHEELS
2 4/40 MOUNTING BOLT SET DU 127 CANOPY HATCH
1 OHIO SUPERSTAR (medium) TAILWHEEL
WINGS
4 4/40 THREADED RODS DU 144 AILERON PUSHRODS
4 4/40 KWICK LINKS DU 305 AILERON PUSHRODS
4 NELSON CONTROL HORN RCL 70 AILERONS
14 HINGES GD 202 AILERONS
2 6/32 X 1 ½ SOCKET HEAD CAP DU 317 WING RETAINER
2 #6 FLAT WASHER DU 327 WING RETAINER
2 6/32 BLIND NUT DU 136 WING RETAINER
TAIL GROUP
2 4-40 THREADED RODS DU 144 ELEVATORS
2 KWICK LINKS (solder) DU 305 ELEVATORS
2 NELSON CONTROL HORN RCL 70 ELEVATORS
12 HINGES GD 202 ELEVATORS, RUDDER
15

2 NELSON CONTROL HORN GD 202 RUDDER
2 4-40 x 3/4 “ SOCKET HEAD CAP DU 572 STAB RETAINER
2 #4 FLAT WASHER DU 323 STAB RETAINER
2 4-40 THREADED RODS DU 144 RUDDER
2 KWICK LINKS (solder) DU 305 RUDDER
1 4-40 THREADED ROD TAILWHEEL
1 KWICK LINK (solder) TAILWHEEL
1 KWICK LINK (threaded) TAILWHEEL
1 STRIPO AILERON HORN TAILWHEEL
16

HARDWARE PACKAGE
PACKING LIST
31% Edge 540 T
8 4/40 x ¾ bolts DU 572
12 4/40 blind nuts DU 135
14 #4 flat washers DU 323
4 10/32 x ¾ bolts DU 580
4 #10 flat washers DU 586
4 10/32 blind nuts DU 584
4 4/40 x ½ bolts DU 571
2 4/40 x 1 ¼ bolts CA 0420
2 5/32 axles DU 248
4 5/32 collars DU 140
2 3” kavan wheels 0164
1 Ohio med tailwheel Tailwheel
9 4/40 threaded rods DU 144
9 4/40 kwick links solder DU 305
8 Rocket city swivel horn RK 01A
2 Packages hinges DU 257
2 6/32 x 1 ½ bolts DU 317
2 6/32 blind nuts DU 136
2 8/32 nuts DU 563
2 #8 flat washers DU 327
1 Threaded kwick link DU 601
1 Strip aileron horn set DU 103
1 4/40 pull pull DU 518
17