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: (732)424-6400

Website: www.airfoilz.com

e-mail: info@airfoilz.com

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.

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Align the tab on the upper

rear double flush with the

skin surface.

Step 5

Glue the servo supports in

place with foam safe CA.

Step 6

Trim off the top front

doubler alignment tab flush

with the upper rear

doubler.

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Repeat Steps 1 to 3 for the other skin assembly making sure to make a

LEFT and a RIGHT side version!

Step 7

Dry assemble all the

plywood crutch pieces and

check for fit. The pieces

should snap together and

self align. If the fit is tight,

lightly sand the notches for

a snug fit.

Step 8

Glue the plywood crutch

parts and landing gear

mount parts together with

medium CA. Insert foam

formers and glue in place

with medium foam safe CA.

TIP: tack glue the plywood

pieces in place with thin CA

then re-glue with medium

CA.

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Landing Gear Mount

Assembly

Glue the plywood landing

gear mount in place with

medium CA.

Glue the landing gear wire

support in place with

medium CA making sure

that the holes in the landing

gear mount align with the

opening in the landing gear

wire support.

Glue the landing gear wire

torsion support in place

with medium CA making

sure the slot in the support

aligns with the hole in the

landing gear mount.

TIP:

Insert a piece of 3/32 wire

into the hole and use as an

alignment guide.

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Glue the landing gear wire

torsion support cap in place

with medium CA. Repeat

for the other side.

Glue the crutch bottom

support in place with

medium CA.

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Step 9

Test fit the rudder servo in

the crutch. Trim the

opening as necessary to

match the servo.

Step 10

Test fit the skins on the

crutch and check that the

slot in the rear of the skin

mates with the alignment

tab on the rear of the

crutch.

Step 11

Glue the crutch to one skin

assembly from the nose to

just behind the wing

opening with medium foam

safe CA. After the glue has

set, glue the skin to the

lower crutch member from

the wing opening to the rear

tab, making sure the rear

alignment tab is properly

seated in the slot. Make

sure the rear of the upper

crutch does not interfere

with the slot for the

horizontal stabilizer.

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Repeat Steps 10 and 11 for the other skin.

Step 12

Glue the top rear edges

of the fuselage together

with medium foam safe

CA .

Step 13

Test fit the rear top deck

and canopy filler pieces

and glue in place with

medium foam safe CA.

Step 14

Glue the front top deck in

position with medium foam

safe CA.

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Tip: Before gluing, lightly

score the backside of the

top skin with an old

ballpoint pen where the skin

is to be bent around the

nose. This prevents

without cracking of the

foam. Pre-bend the foam

before gluing in place.

Step 15

Trim the front of the top

deck piece and glue in a

3/8” wide scrap piece of 3

mm foam for support with

foam safe CA.

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Step 16

Epoxy the motor mount in

place making sure it is flush

and square with the motor

mount support. TIP: Mark

the motor mounting hole

locations before gluing the

motor mount in place.

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Step 17

Glue the bottom cowl skin

in place with medium foam

safe CA. Tip: Before gluing,

lightly score the backside of

the bottom skin with an old

ballpoint pen to allow the

foam to be bent around the

nose without cracking. Pre-

bend the foam before gluing

in place.

Step 18

Trim the bottom cowl piece

and glue in a 3/8” wide

scrap piece of 3 mm foam

for support with foam safe

CA.

Step 19

Glue the lower fuselage

skin in position with

medium foam safe CA.

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Step 20

Glue on the ¼” x ¼” tail

post with medium foam safe

CA.

Step 21

Finish the fuselage

construction by sanding the

edges smooth.

Wing Assembly and Installation

Assembling the Spar:

AirfoilZ EDGE 540 User manual