Carl Goldberg Products Edge 540 ARF User manual

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INSTRUCTIONS
WARNING
A radio-controlled model is not a toy and is not intended for persons under 16 years old. Keep
this kit out of the reach of younger children, as it contains parts that could be dangerous. A radio-
controlled model is capable of causing serious bodily injury and property damage. It is the buyer's
responsibility to assemble this aircraft correctly and to properly install the motor, radio, and all other
equipment. Test and fly the finished model only in the presence and with the assistance of another
experienced R/C flyer. The model must always be operated and flown using great care and common
sense, as well as in accordance with the Safety Code of the Academy of Model Aeronautics
(www.modelaircraft.org). We suggest you join the AMA and become properly insured prior to flying
this model. Also, consult with the AMA or your local hobby dealer to find an experienced instructor in
your area. Per the Federal Communications Commission, you are required to use only those radio fre-
quencies specified "for Model Aircraft."
LIMITED WARRANTY
Carl Goldberg Products has inspected and certified the components of this aircraft. The company urges the buyer to perform his
own inspection, prior to assembly, and to immediately request a replacement of any parts he believes to be defective for their
intended use. The company warrants replacement of any such components, provided the buyer requests such replacement with-
in a period of 90 days from the date of purchase and provided the defective 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 buyer acknowledges and under-
stands that it is his responsibility to carefully assemble the finished flying model airplane and to fly it safely. The buyer hereby
assumes full responsibility for the risk and all liability for personal or property damage or injury arising out of the buyer's use of the
components of this kit.
CARL GOLDBERG PRODUCTS, LTD.
P.O. Box 818 Oakwood GA 30566 Phone #[phone] Fax # [phone] www.carlgoldbergproducts.com
© Copyright 2005 Carl Goldberg Products LTD
TM
77” Edge 540 ARF

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Congratulations on your purchase of the 77”
Edge 540 ARF. Every effort has been made to
produce a lightweight, straight, easy to assem-
ble aircraft. Because of its oversize control sur-
faces which are double beveled to allow for
extreme throws, great care must be taken in the
set-up and flying of this airplane. Quality hard-
ware components have been provided to allow
for 3D set-up while maintaining adequate
mechanical advantage to eliminate flutter. It is
your responsibility as an advanced pilot to fly
the aircraft in an intelligent manner. THROTTLE
MANAGEMENT IS A MUST!!!!!!! Carl
Goldberg Products has flown the 77” Edge
540 ARF through a very rigorous flight-testing
schedule and have stressed the airframe
beyond all practical parameters without a single
failure. Carl Goldberg Products will NOT war-
ranty the 77” Edge 540 ARF against flutter due
to improper set-up or excessive speed maneu-
vers. having said that, we believe you will find
the 77” Edge 540 ARF to be one of the most
responsive, in-the-grove aircraft on the market.
Just remember to use common sense when fly-
ing this high performance machine.
We are very proud of the construction of the 77”
Edge 540 ARF and all of our other ARF aircraft.
Each aircraft is jig built to insure a straight true
airframe. Every effort is made to build as light an
aircraft as possible. As with any professional
builder, glue is used sparingly. Please take a
moment during assembly and run a bead of
CA or aliphatic resin into the high stress
joints that you can reach such as the landing
gear plate, servo mounting trays, wing hold
down blocks, Firewall, etc. Also, during the
course of shipping from the manufacturer to our
facility in the United States, it is not uncommon
for the aircraft to experience several changes in
climate. This may cause the iron-on covering to
develop wrinkles. This is not a fault of the manu-
facturer. Please take a few minutes with your
heating iron and heat gun to iron down the
seams and re-shrink the covering where needed.
The results will be a beautiful aircraft with a
breathtaking finish that you will be proud to dis-
play at your flying club.
Before beginning assembly of your 77” Edge
540 ARF, we highly recommend that you study
this manual in its entirety. You should begin
planning your radio installation based on your
choice of engine and equipment from the begin-
ning.
Because the 77” Edge 540 ARF is intended
for those with some degree of modeling
experience, every minute detail will not be
covered. This is not a basic trainer.
Assembly of this aircraft will be easy for the
experienced modeler, and by following the
instructions within this manual and using
the skills you’ve gained during your model-
ing career you will be able to produce a first
class aircraft.
Building supplies needed
Hobby knife w/#11 blades
Thin CA
Medium CA
Canopy glue
30 minute epoxy
Thread lock
Diagonal wire cutters
Pliers
Assorted drill bits
Various sized screwdrivers( both Phillips and
standard head)
Tape measure
Dry-erase marker
Paper towels
Rubbing alcohol
Electrical tape
4-40 Tap & Die Set
3/32, 7/64, 9/64 & 3mm Allen wrench
Wax Paper
3-1 Oil
Note:
Thread lock must be used where
ever any machine bolts are threading
into any type of nuts. If you do not
use thread lock the bolts could
become loose and fall out in flight.

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ADHESIVES & GLUING TECHNIQUES
CA adhesives are specially formulated to firmly glue the
plywood, hardwood, and balsa used in your model and to
withstand the vibration and stresses of high performance
flight. However, there are times, such as when you are
installing the stabilizer and fin on the fuselage and want
more set-up time for careful alignment and positioning,
then you should use epoxy. Occasionally, you also will
want to use thin CA, which "wicks" into the surrounding
areas. Aliphatic resin glue or similar water-based glues can
also be used, but they will add to the assembly time
because they dry so much more slowly than CA glue.
Remember, when ever using any CA, you must be careful
to read instructions thoroughly, as you will have only sec-
onds for positioning of parts. Be sure to trial fit parts
together before gluing. Also, never use watery THIN type
CA glue for gluing plywood and hardwood parts. Thin CA's
do not adequately bond these areas.
CAUTION
Some people may experience an allergic reaction when
exposed to fumes from CA glue or epoxy. As with paints,
thinners, and solvents, it is always important to use glues
only where there is adequate ventilation to carry fumes
away. A fan is recommended. Also, special care must be
taken when using CA, as it will bond skin as well as other
surfaces. Before using any CA, carefully read all label pre-
cautions. When using CA, protective eye-wear and care in
keeping the glue away from the face is highly recommend-
ed. If CA does happen to get into the eye, hold lid open
and flush with water only. Seek immediate medical atten-
tion.
CONSTRUCTION TIPS
IMPORTANT: ALWAYS READ A FEW STEPS AHEAD.
This will alert you to coming instructions and will help you
plan accordingly.
COVERING
The 77” Edge 540 ARF is covered in a premium polyester
film chosen by many of the world's top flyers for its beau-
ty, toughness, and ease of application and repair. It is not
uncommon for ARF's to develop a few wrinkles in transit.
If this is true of your model, the situation is easily correct-
ed. Before you begin putting the pieces together, run
around the edge of the seams first then over the surface
of each section with an iron (either specially designed for
airplane use or the more cumbersome household iron).
Apply the heat (set at about 350° F), following along with
a soft cloth and pressing down on the covering as you go
around. This will more firmly set the covering adhesive
into the wood and keep your aircraft covering tight and
smooth in the future. Once you have ironed the seams
stay away from them with the heat or the covering will
slide when you try to shrink the middle. If this happens the
wrinkles will not come out of the covering.
ITEMS NEEDED TO COMPLETE THIS AIRCRAFT
 24” FUEL LINE
 ENGINE ..1.2O TO 2.4
1 RADIO GUIDANCE SYSTEM 
2 12” AILERON SERVO EXTENSION WIRES
3 11” SERVO Y-CONNECTORS
1 CA ACCELERATOR
1 2 OZ. BOTTLE CA MEDIUM GLUE
1 1/2 OZ. BOTTLE CA THIN GLUE
1 30 MINUET EPOXY
1 1/2” FOAM RUBBER
1 3-1/2” SPINNER
OPTIONAL:
1 PILOT FIGURE
SERVO ARM EXTENSIONS
NOTE: The 77” Edge 540 ARF covering closely
matches Ultra Coat:
Bright Yellow #872
True Red #866
Sliver #881
Black #874

3. Using a 1/8” drill, drill half way through the
aileron hole from both top and bottom till the
drill passes through the aileron.
Insert the 6-32 x 3” bolt into the top of the
aileron.
Thread the bolt all the way till the head is flush
with the top of the aileron.
4. On the bottom of the aileron, place first the
cup washer then the nylon nut onto the 6-32
bolt.
Using a screwdriver tighten the nylon nut all
the way down till it rest in the cup washer and
is tight to the aileron.
Thread the nylon adjustable control horn onto
the bolt.(Note: Thread the side that you can
see the cut threads in the nylon onto the
bolt)
2. With the aileron servo in place, make a mark
on the aileron at a 90º degree angle to the
trailing edge and in line with the servo. Look
for the control horn hard point under the cov-
ering. This is the location for the control horn.
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AILERON CONTROL HORN INSTALLATION
1. Collect the following items
(4) 4-40 x 3” socket head bolt
(4) Nylon Adjustable Control horns
(4) Nylon Nut
(4) Nylon Cup Washer
CONTROL HORN PART NAMES
WING ASSEMBLY
6-32 x 3” bolt
adjustable control
horn
nut washer
Transfer the mark from the bottom of the
aileron to the top side.

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2. Trial fit the hinges into the holes on both the
aileron and wing.
If necessary use a 7/32” drill in each hole 1/8”
deep to allow the shoulder of the hinge to go in
Make sure all hinges insert half way.
3. Place 1 drop of oil on each of the hinge joints
at the center. This is to keep the hinges loose
and prevent epoxy from sticking at the joint.
Caution: Do not get any oil on the length of the
hinge or it will not glue into the surface.
AILERON INSTALLATION
1. Collect the following parts:
(1) Left wing
(1) Right wing
(1) Left aileron
(1) Right aileron
(10) hinges
(2) 1/4-20 nylon wing bolts
4. Select the aileron for the wing half on which
you are working.
Mix up a liberal amount of 30 minute epoxy.
Using a piece of wire or a toothpick, work
some epoxy into each hole on the wing and
aileron.
Working with 1 hinge at a time, place a dab of
epoxy and insert the hinge half way into one of
the aileron holes.
Repeat for each of the other hinges for that
aileron.
5. Working quickly, place some epoxy on the
second half of each hinge and insert the
aileron into the wing.
Slide the aileron toward the wing until no gap
remains between the aileron and the wing.
When satisfied with the alignment, flex the
aileron up and down to confirm that the hinges
are working freely. remove any excess epoxy.
Apply a few strips of masking tape to keep the
pieces in place.
Allow to dry before flexing the aileron.
6. Repeat the above steps for the other half of
the wing.
AILERON SERVO INSTALLATION
1. Collect the following parts:
(1) Left wing
(1) Right wing
(4) Servos
(2) Servo “Y” Harness
5. It is important when two servos are to the
same aileron that both control horns are equal
length.
Measure from the center of the hinge line to
the top of the nylon control horn bracket and
adjust both to be equal.

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2. Attach the outboard servo to one side of the
Y-connector. Insert the Y-connector into the
outboard hole and guide down the wing to the
inboard servo hole. Pull the other side of the
y-connector through the hole and connect the
other servo. Continue pulling the y-connector
to the center of the wing.
Screw the two servos into place with the out-
put arms forward, using the hardware sup-
plied with the radio.
IMPORTANT! To ensure that any connections locat-
ed inside the wing will not come loose, either when
the wires are pulled, or during flying, always tape
them securely together with electrical tape.
3. Tape the end of the plug to the root rib.
Repeat for the other wing half.
Aileron Servos Pushrods
1. COLLECT THE FOLLOWING ITEMS:
(4) 4-40 X 3-1/8” PUSHRODS THREADED
BOTH ENDS
(4) 4-40 CLEVIS
(4) SILICONE CLEVIS RETAINERS
(4) 4-40 nuts
3. Repeat for the other three servos
2. Screw the 4-40 x 3-1/8” pushrod into the nylon
control horn fitting on the aileron.
Slide the silicone clevis retainer over the end
of the clevis.
Screw the nut then the clevis on the other end
of the pushrod.
Center the servo with the radio, make sure the
aileron is centered and adjust the clevis to fit
on the servo output arm.
After final adjustment, tighten nut against cle-
vis and put thread lock on nut.

WHEEL AND WHEEL PANTS
1. Collect the following items:
(2) 5-32 x 1-1/4” Axle with Locking Nut
(4) 5/32 Wheel Collars
(6) 6-32 x 1” Cap Screws
(2) 4-40 Blind Nuts
(2) 4-40 x 1/2” Button Head Screws
(2) 3-1/4” Wheels
(2) Landing gear legs
3. Mount the axle to the landing gears.
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FUSELAGE HATCH
The top front half of the fuselage is a hatch. Remove
the 4-40 socket head bolts on the side of the fuse-
lage to disengage the hatch.
2. Insert the gear legs through the slots in the
fuselage side.
Use the six 6-32 x 1” bolts to secure the gear.
The blind nuts are already installed in the
fuselage.
Be sure and use thread lock on the bolts.

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4. Install the blind nut in the wheel pant using the
4-40 bolt to pull it into the hole.
Wheel Collars
Wheel Pant
Wheel
Landing Gear
5. Mount the wheel pant on the landing gear
along with the wheel collars and wheels.
Center the wheel on the axle.
Use the 4-40 x 1/2” bolt to hold the wheel pant
to the gear. Be sure to use lock-lock on the
bolts.
HINGING RUDDER
1. Locate the rudder and four hinges
Trial fit the hinges to make sure they all go up
to the hinge pin in rudder and fin.
2. Trial fit the rudder in place on the fin. Make
sure the hinge line is tight and the counter bal-
ance does not rub on the top of the fin.
Insert a piece of wire into the outlet hole for
the rudder cable (holes are just below the ele-
vator servo cutout) and make a mark on the
rudder in line with the outlet hole.
3. Transfer the mark to the other side of the rud-
der
Drill a 9/64” hole at the location marked. Drill
half way from each side until the hole is com-
pletely through.

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4. Install the 6-32 x 3-1/2” threaded rod in the
hole with a nylon washer and nylon nut on each
side
Thread the nylon fitting for the tail wheel steer-
ing on each end first, then the control horn fit-
ting.
5. Mix some 30 minute epoxy and apply some in
the holes in the rudder and fin using a tooth pick
or piece of wire.
Apply a drop of oil to each hinge. Put a dab of
glue on the end of each hinge and install.
Fit the rudder in place and work back and forth
several times to rotate the hinges in place.
Use tape to hold the rudder in place till the glue
dries.
Tail Wheel Bracket Installation
1. Collect the following parts:
(1) Tail wheel spring bracket
(1) Tail wheel axle
(1) 1” rubber tail wheel
(1) 1/8” wheel collar
(2) bracket collars
(2) nylon horn brackets
(2) 3mm screws
(2) 2mm x 1” threaded rods
2. One of the bracket collars has two holes
threaded into it, one on each side. This one is
the top one.
Put the bottom bracket collar on the axle and
insert it through the spring bracket.
Put the top collar bracket on top and tightened
the two set screws.
3. Screw one of the two threaded rods on each-
side of the top bracket collar.
Screw the nylon horn fittings on each end of
the threaded rod.
4. Put the tail wheel on the axle and retain with
the wheel collar.
5. Mount the tail wheel assembly on the rear of
the fuselage using the two 3mm screws.
Drill a 1/16” pilot hole at each spot.
Make sure to put the bracket far enough forward
to allow the rear screw to go into the hardwood
plate and not just the balsa wood of the fin post.

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3. Make a mark 1/4” inboard from the center of the
stab and 1/8” back from the top of the bevel.
Transfer this mark to the other side of the stab.
Using a 1/8” drill, drill the hole for the control
horn.
4. Install the 6-32 x 3-1/2”” bolt, nylon washer,
nylon nut, and tighten down.
Install the pushrod fitting on the end.
Repeat for the other elevator.
5. Hinge the elevators in place using the same
method we did on the ailerons and rudder.
Stabilizer and Elevator Installation
1. Collect the following parts:
(2) stab halves
(2) elevator halves
(8) hinges
(2) 6-32 x 3-1/2” control horn bolts
(2) nylon nuts
(2) nylon washers
(2) adjustable control horns
2. The two inboard hinges will have to be cut off
1/2” because of the rear aluminum tube.
Trial fit the elevators to the stab and make
sure all hinges will go in half way.
6. It is easier to mount the elevator servos now
before mounting the stab.
Connect a 12” extension to each servo and
mount in the holes with the output arm forward.