AirfoilZ EDGE 540 User manual

EDGE 540 Full Fuse
Assembly Manual
Specifications
Wing Span: 40 inches
Wing Area: 350 in2
Fuselage Length: 35.6 inches
Weight (ready to fly): 19 to 23 oz.
Wing Loading: 7.8 to 9.5 oz/ft2
Designed by Jim Vigani
Version 1.0 – 7/31/09

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A Tech Hobbies,LLC Company
532 North Avenue
Dunellen, New Jersey 08812
Ph: [phone]
Website: www.airfoilz.com
e-mail: [e-mail]
© Copyright 2009 all rights reserved
Limited Warranty
AirfoilZ takes pride in the care and attention given to the manufacture of the components in this
kit. The company warrants replacement of any materials found to be defective for their intended
use prior to their use in the construction of the model, provided the purchaser requests such
replacement within a one year period from the date of purchase, and the part is returned, if so
requested by the Company. No other warranty, expressed or implied, is made by the company
with respect to this kit. The purchaser assumes full responsibility for the risk and all liability for
personal or property damage or injury resulting from the purchaser’s use of the components of
this kit whether assembled or not.
The Company reserves the right to provide a full refund to the purchaser if the model does not
perform as advertised. Any refund is at the sole discretion of the Company.

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Introduction:
Thank you for choosing the AirfoilZ Edge 540 model airplane. We have taken great care to provide
a design and kit components that, when properly assembled, will give you a high quality model with
outstanding performance. While the assembly is not complicated, the quality and ultimate
performance of your model will depend on the care you take while building. Please read these
instructions carefully and be sure that you understand them before you start. Take care to
assemble the components as shown and in proper alignment. Please note that some of the parts
shown may be different in material from those provided in the kit. The installation of these
parts is unaffected by the material change.
Warning
This radio-controlled model is not a toy and, if operated inappropriately can cause serious
bodily injury and property damage. It is the buyer’s responsibility to assemble the kit correctly
and properly install the motor, radio and all other equipment. The model must always be flown in
accordance with the safety standards of the Academy of Model Aeronautics (AMA).
This model is designed for high performance. While it is reasonably simple to assemble, it is not
intended for the novice flier. Do not attempt to learn to fly with this model! If you are an
inexperienced modeler, we recommend that you get the assistance of an experienced modeler to
help you with the assembly and initial flights. There are many local clubs that can offer help with
assembly and flight instruction. Information on local clubs can be found through the Academy of
Model Aeronautics. The AMA has over 2500 chartered clubs throughout the country. Information
on the AMA can be found at www.modelaircraft.org.
We do not recommend the use of hot glue for mounting components such as servos, control horns,
receivers or speed controls.
Recommended Power System:
This plane has been designed to use a 200 to 300 watt power system. Recommended motors
include the Common Sense E5-L-13, Scorpion SII-3008-1090, or AXI 2808-24 with a 25 to 35 amp
speed controller, and a 1800 to 2200 mAh, 3S Li-poly battery with a 10x5 to 11x5.5 propeller. Other
power systems with similar capabilities can be used. Performance will vary depending on the
specific power system selected. For information on alternate power systems please visit
http://3dxhobbies.com or your local hobby shop.

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Kit Contents:
Before you start the assembly of this model, check to make sure that there are no missing parts and
that none of the parts have been damaged during shipment. If you have any questions with the
assembly or flying of this model, please contact us and we will be happy to assist you. If you need
replacement parts please provide the model name. The foam and wood parts included in the kit are
shown on the Part Sheet included with the kit.
Other items you may need that are not included with your kit:
Building Supplies:
In addition to the kit contents, we recommend having the following building supplies on hand to
complete the kit assembly in accordance with this manual.
Foam safe (odorless) CA
Foam safe CA “Kicker”
Thin CA
Gorilla glue
5 and 15 minute epoxy
Double back tape or spray adhesive
Low tack masking tape (blue painter’s tape)
Sanding block with 100 grit sandpaper
Sanding stick or emery board (150 grit)
Soldering iron and resin core solder
1/32 inch and 1/16 inchdiameter drill bits
Exacto knife with #11 blade
Utility knife
Small square
36 inch ruler
Needle nose pliers
3/8 inch diameter brass tubing
Diagonal cutting pliers
Power and Control Equipment:
The following items are needed to provide power and control function to your model.
Brushless outrunner motor with radial mount
4 motor mounting screws
Brushless motor speed control
4 micro servos (Hitec HS55 or equivalent)
3S Li-poly battery pack
LI-poly battery charger
4 or 6 channel micro receiver
Y harness if a 4 channel receiver is used
3 to 6 channel transmitter

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Making a Sanding Block:
The leading edges of the elevator, the rudder, and both ailerons need to be beveled prior to
installing the hinges. This is best performed by the use of a 2-inch wide by 12 inch long, 100 or 120
grit sanding block or sanding bar. In addition, other areas of the airframe need to be sanded as
shown in this manual to complete the assembly and enhance appearance. If you do not have a
suitable sanding block, one can be easily made by securing a piece of 100 grit sand paper to a 2
inch x 12 inch x ¾ inch wooden block. The sandpaper can be secured to the block using either
double backed tape or spray adhesive. Make sure that the block is flat! A styrofoam block is
great for general sanding of the fuselage and non-beveled edges of the control surfaces.
Figure: 1
Figure: 2
Figure: 3
General Comments on Assembly:
While not difficult to assemble, the Edge 540 kit is intended for persons with some building
experience. As such, the instructions are presented as a simple sequence that, when followed, will
help ensure that the airframe turns out straight and light. Improperly aligned surfaces and
unnecessary weight will only hinder its performance. Apply glue and epoxy in a thin uniform coat,
using only enough to achieve a strong bond. Excess glue or epoxy will only add unnecessary
weight and will not increase the strength of your model. Trial fit all components to ensure fit and
alignment before applying any glue or epoxy. Keeping joints tight fitting will minimize the amount of
glue required and will ensure a strong bond. When gluing foam to foam, or foam to wood, use

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only foam safe CA and foam safe kicker. There are two basic methods that can be used when
gluing flat pieces of foam together such as when gluing the foam doublers to the fuselage skin. The
first method involves applying CA to the smaller part, positioning it in place and then spraying a light
spray of foam safe kicker along the perimeter of the part. The second method involves applying CA
to the smaller part, and lightly spraying the mating part with foam safe kicker. The parts are then
joined.
Use a light touch while sanding. Foam cuts very quickly and excess pressure can limit your ability to
accurately shape the foam. Take extra care not to over sand. Avoid scratching the surface of the
Depron foam.
Graphics:
The Edge 540 comes with printed vinyl graphics. Extra care in cutting out and applying the vinyl
panels will result in a painted look for your plane. Some people prefer to lightly mist the surface with
“Frebreze” before applying the vinyl. This allows the vinyl to be repositioned while applying them.
Fuselage Assembly:
The fuselage assembly on the Edge 540 consists of a plywood and foam crutch assembly covered
with a depron skin.
Fuse Assembly

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Skin Assembly
Skin Component Parts

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Crutch Assembly
Follow the steps in the order outlined below to ensure accurate alignment of the
components.

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Step 1
Glue the wing root doubler
in place with foam safe CA
being careful to ensure the
wing openings are in
perfect alignment.
Tip:
Before joining, apply CA to
the doubler and lightly
spray kicker on the fuse
skin.
Step 2
Using the plywood nose
doubler as a guide, glue
the top front doubler in
place with foam safe CA.
DO NOT GLUE THE
PLYWOOD NOSE
DOUBLER IN PLACE!
NOTE: The top front
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
help ensure proper
alignment.

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Step 3
Glue the lower rear doubler
in place with foam safe CA.
NOTE: The lower rear
doubler needs to be
positioned 3 mm from the
edge of the skin. An
alignment tab is provided
at the rear of the part to
ensure proper alignment.
Step 4
Glue the upper rear
doubler in place with foam
safe CA.