Extreme Flight RC 75" Edge 540 ARF User manual

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75" Edge 540 ARF
Assembly Manual
Copyright 2018 Extreme Flight RC

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Please take a few moments to read this instruction manual before beginning assembly. We
have outlined a fast, clear and easy method to assemble this aircraft and familiarizing
yourself with this process will aid in a quick, easy build.
Please read the following paragraph before beginning assembly
of your aircraft!
THIS IS NOT A TOY! Serious injury, destruction of property, or even death may result
from the misuse of this product. Extreme Flight RC is providing you, the consumer, with
a very high quality model aircraft component kit, from which you, the consumer, will
assemble a flying model. It is beyond our control to monitor the finished aircraft you
produce. Extreme Flight RC will in no way accept or assume responsibility or liability for
damages resulting from the use of this user assembled product. This aircraft should be
flown in accordance with the AMA safety code. It is highly recommended that you join
the Academy of Model Aeronautics in order to be properly insured and operate your
model at AMA sanctioned flying fields only. If you are not willing to accept ALL liability
for the use of this product, please return it to the place of purchase immediately.
Extreme Flight RC, Ltd. guarantees this kit to be free of defects in materials and
workmanship for a period of 30 DAYS from the date of purchase. All warranty claims
must be accompanied by the original dated receipt. This warranty is extended to the
original purchaser of the aircraft kit only. Extreme Flight RC in no way warranties its
aircraft against flutter. We have put these aircraft through the most grueling flight tests
imaginable and have not experienced any control surface flutter. Proper servo selection
and linkage set-up is absolutely essential. Inadequate servos or improper linkage set up
may result in flutter and possibly the complete destruction of your aircraft. If you are not
experienced in this type of linkage setup or have questions regarding servo choices, please
contact us at [e-mail] or 770-887-1794. It is your responsibility to
ensure the airworthiness of your model.

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Congratulations on your purchase of the 3DHS 75" Edge 540 ARF!
The original 3DHS 74" Edge 540 was a legendary airframe among devotees of 3D
Aerobatics. It was beloved due to its ability to be both stable and gentle for 3D newbies
yet aggressive and satisfying for the more experience flyer. Now the 3DHS Edge 540 has
been updated to current specifications with generous use of carbon and composites to
strengthen the airframe while keeping the weight low. The cowl has been remodeled to
the latest high performance racing design borrowed from the Edges that currently
dominate the air race series. Little has changed however in the basic aerodynamic
package that the Edge is built around as it has more than proven itself. The Xpwr 30 is
the ideal complement for the Edge, its diminutive size and weight belying its brute
strength and power! Coupled with the Castle 80 or 120HV, 12S 3300-3700 mah high C
rating batteries and a Xoar 20x8 PJN, the Edge has extreme power for any maneuver
imaginable!
Items needed for completion:
✓Masking tape.
✓Hobby knife with #11 blades.
✓Thin and medium CA. We highly recommend Mercury M5T thin and M100XF
medium formulas as well as the Mercury glue tips.
✓30 minute epoxy. Pacer Z-poxy is a long time favorite.
✓Pacer Formula 560 Canopy Glue
✓Blue Loctite.
✓Electric drill with an assortment of small drill bits.
✓Flat head and Phillips head screw drivers.
✓Standard and needle nose pliers.
✓Side cutters.
✓Metric ball driver or allen key set.
✓Sanding block and sandpaper.
✓4 x METAL GEARED servos with a minimum of 300 oz/inches of torque. All flight
testing was performed with MKS 1220 servos.
✓Extreme Flight aluminum servo arms: 3 1.5 inch arms (2 for ailerons, 1 for elevator)
and 1 3" dual arm for the rudder.
✓2 x 6” Servos Extensions for the Ailerons.
✓2 x 24” Servo Extensions for the elevator and throttle servo or ESC lead.
✓Xpwr 30cc brushless outrunner motor
✓Blazing Star Standard XL standoff kit for electric motor mounting
✓Castle Creations 80 or 120 HV ESC.
✓Receiver battery
✓2-6S 3300-3700 mah LiPo battery hooked up in series for 12S operation
✓Xoar 20x8 PJN electric prop.
✓DA-35 with muffler if using a gas engine.
✓EF 3.5" CARBON FIBER spinner with aluminum backplate.

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Tips for Success:
1. Before starting assembly, take a few minutes to read the entire instruction manual
to familiarize yourself with the assembly process.
2. Please take a few minutes and go over all the seams on the aircraft with a covering
iron on a medium heat setting. Also, due to climate changes, wrinkles may develop
in the covering. These are easily removed with a little bit of heat. Use a 100%
cotton tee-shirt and your heat gun and heat the covering while gently rubbing the
covering onto the wood with the t-shirt. Be careful not to use too much heat as the
covering may shrink too much and begin to lift at the edges. Take your time, and a
beautiful, paint-like finish is attainable.
3. Apply a bead of Pacer Formula 560 Canopy Glue at the intersection of the plastic
canopy and its wooden frame.
4. We are very pleased with the level of craftsmanship displayed by the builders in our
factory. Through hundreds of grueling test flights containing maneuvers that no
aircraft should be subjected to, our prototypes have remained rigid and completely
airworthy. Having said that, it is impossible for us to inspect every glue joint in the
aircraft. Take a few minutes and apply some CA to high stress areas such as the
aileron servo mounting trays , landing gear mount, anti rotation pins, wing and stab
root ribs and motorbox joints.
5. By the time your aircraft arrives at your door step, it will have been handled by a lot
of people. Occasionally, there are small dings or imperfections on some of the
surfaces. An effective method to restore these imperfections to original condition is
to use a very fine tipped hypodermic needle and inject a drop of water under the
covering material and into the ding in the wood. Apply heat to the area with a
sealing iron and the imperfection will disappear. Deeper marks may require that
this process be repeated a couple of times to achieve the desired result, but you will
be surprised at how well this technique works.
6. Use a high quality epoxy for installing the composite control horns. We highly
recommend Pacer Z-poxy. We are very pleased with the results and ease of
application and cleanup of this product.
7. When applying decals, first clean the area where the decal will be applied with
alcohol. Mist the area lightly with Windex or Rapid Tack before applying the decal
which will allow you to properly position it, and then use a rubber squeegee to push
all of the liquid from under the decal. This will result in very few air pockets
trapped under the decal.
8. Take the time to properly balance and trim your aircraft and set up rates and
exponential values. Your flying experience will be greatly enhanced once your plane
is properly dialed in.

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Let's begin!
1. Locate the 2 wing panels as well as the composite aileron control horns and base
plates. Use a soldering iron or sharp hobby blade to remove the covering over the
slots for the aileron horn and aileron servo mount as shown. Make sure you are
doing this on the bottom of the wing and aileron!
2. Scuff the portion of the horn that will glue into the aileron and secure with 30
minute epoxy. Wipe away any excess glue with an alcohol soaked rag. Insert the
ball link between the horns to ensure proper alignment while the glue dries.

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3. Inspect the hinges and make sure that each hinge is seated properly. Adjust any
hinge holes that are impeding movement. Remove all of the hinges from the wing and
aileron. Mix a generous batch of 30 minute epoxy. Use a zip tie or an old pushrod to
thoroughly coat and fill the hinge holes in the wing with epoxy. Coat one side of each
hinge with epoxy and insert it into the wing taking great care to make sure it is
centered properly. Wipe away any excess glue with an alcohol soaked rag or paper
towel. Once all hinges are installed in the wing set it aside to dry.
4. Once dry use the same procedure to fill the hinge holes in the aileron with epoxy.
Coat the protruding hinges with epoxy then slide the aileron into position. Make sure
the aileron is seated properly with minimal gap between the wing and aileron and wipe
away any excess glue with an alcohol soaked rag. Pay careful attention to wipe any
excess glue from the hinge knuckle. Set the assembly aside to dry. Once dry the
aileron movement may feel a bit stiff. A drop of Acetone placed on the knuckle of each
hinge will help to free the aileron. Then apply a drop of Teflon or silicon lubricant to
each hinge and work it into the joint by moving the aileron back and forth multiple
times. Wipe away any excess lubricant with an alcohol soaked rag. Now is a good time
to seal the hinge line gap with Blenderm tape or Oracover (Ultracote) if you desire to
do so.
5. Secure a 6 inch servo extension to the aileron servo lead and install your aileron
servo as shown with the output shaft oriented toward the leading edge of the wing.

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6. Assemble the aileron linkage as shown and secure to the aileron horn assembly
and servo arm with the provided 3mm bolts. Apply blue Loctite to all bolts!
7. Repeat this process for the other wing, then inspect them both for taut covering
and any lifting seams that need attention with a hot iron or heat gun. Give a good tug
on the aileron to make sure all is secure, then clean the wings with a soft cloth and
Windex and set aside.
Fuselage Assembly
8. Locate the carbon fiber landing gear and mounting bolt set in the hardware bag.
Insert each bolt into a washer, through the carbon gear and fuselage and secure with
a nylon insert locknut.

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9. Trial fit the landing gear cuffs to the carbon gear legs and mark their location.
Remove the cuffs and apply a bead of Silicon based Goop glue completely around
the gear leg as shown. Slide the cuffs into place and secure with tape until dry.

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10. Locate the 2 axles, 2 locking nuts, 2 wheels, 2 wheel collars and 2 wheel pants.
Place the wheel on the axel and secure with a wheel collar.
11. Place the threaded portion of the axle through the hole in the landing gear and
secure with the lock nut and washer. Slide the wheel pant into position over the axle
and secure with the provided 3mm bolt. You may need to enlarge the hole in the
wheel pant with a Dremel tool to fit over the axle bolt.

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12. Using the same procedure as the ailerons, glue the hinges in place in the stab and
elevators and install the control horn and baseplate in the bottom right location.
13. Remove the covered wooden block from behind the stab slot and trial fit the stab
into the self aligning slot. Confirm alignment with the main wing tube. Once satisfied
with fit and alignment mix up a batch of 30 minute epoxy and apply to the stab
center. Slide into position and reconfirm alignment. Wipe away any excess glue and
set aside to dry.

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14. Once the stab/elevator assembly is dry glue the covered balsa block back in place
with medium CA or epoxy.

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15. Locate the rudder along with the dual control horn and open ended base plates.
16. Scuff the middle portion of control horns that will be glued into the rudder.
Apply epoxy to the slots in the rudder and to the center of the control horns. Slide
the control horns into position and measure to be sure they are centered. Place a
ball link and 3mm bolt into position to maintain proper spacing between the 2
horns. Apply epoxy to the 2 base plates and slide into position. Remove any excess
glue with an alcohol soaked paper towel, recheck alignment and set aside to dry.

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17. Once the control horn assembly is dry glue the rudder into place using the same
method that you did for the ailerons and elevators.
18. Drill a hole in the bottom of the rudder to accept the shank of the ball link
included in the tailwheel assembly hardware bag. Glue it in place with epoxy. Once
dry install the tailwheel assembly as shown making sure the pivot point is aligned
with the rudder hinge line.
19. Install the rudder servo in the provided location within the fuselage.

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20. Locate the rudder linkage assembly in the hardware package. Assemble the
pull-pull linkage on one end of each of the provided pull-pull cables. This is done by
inserting the cable into an aluminum crimp tube and through the hole in the
threaded brass fitting. Push the cable back through crimp tube and then loop it
around and back through the tube again. Pull tight, leaving a small loop between
the crimp and brass fitting as shown and crimp the aluminum tube in multiple
places with a crimping tool or side cutters. Trim away any excess cable. Repeat for
the second cable. Screw the ball link half way onto the brass fitting to allow for
adjustment once installed.
21. Insert the bare end of the wire into the tube in the rear side of the fuselage and
feed it through to the rudder servo. Secure the ball link to the control horns with the
supplied 3mm hardware as shown. Do the same for the other side of the rudder.
The cables should cross in an X pattern before attaching to a 3 inch double servo
arm with the provided 3mm bolts and nuts.

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22. The firewall on the Edge has laser scribed locations for mounting the Xpwr 30 as
well as the DA-35. Drill at the correct location for your choice of power plant. If using
an alternative motor/engine simply download the mounting template from the engine
manufacturer's website and align with the centering marks on the firewall and drill the
appropriate holes.

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23. We highly recommend the use of the Blazing Star Standard XL Standoff Set to
make the mounting of the Xpwr 30 as fast and easy as possible. All necessary
mounting bolts are included in the standoff set. Distance from firewall face to spinner
backplate is 6.41" or 163mm.
24. There is a designated location on the bottom of the motorbox to mount your ESC.
Be sure to secure the motor wires to prevent chafing.
25. For detailed pictures of a gas engine install please see pages 10-12 in the 74" Slick
580 manual located here: http://extremeflightrc.com/assets/images/products/EF-
74Slick/Manual/74_slick_manual_web.pdf

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26. If using an electric setup, locate the clear motor baffles. Using a pair of scissors cut
the assembly in half and trim. If you decide to paint the baffles be sure to avoid getting
paint on the part that glues to the cowl. Glue the baffles in place with Goop or epoxy.

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27. Once satisfied with the motor/esc installation and proper direction of rotation has
been confirmed, install the cowl by sliding it up onto the lower retaining hooks and
securing with 2 3mm bolts installed through the holes in the F1 former and into the
blind nuts in the cowl. Be sure to put a drop of blue Loctite on the bolts.
28. Attach a 24” servo extension to the elevator servo and secure with EF servo clips
or heat shrink tubing. Use the hardware provided with the servos to install the
elevator servo on the left side of the fuse with the output shaft toward the front of the
aircraft. Assemble the elevator linkage as shown using the provided 3mm hardware
and a 1.5" servo arm.

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29. Here is a picture of the receiver installation and how I have routed the servo
extensions to make a tidy setup.
30. The wings are retained by inserting a 4MM bolt and washer through the tabs on
each wing at the side of the fuse just behind the wing tube. Make sure the wings are
pushed all the way in so the holes in the tab and fuse line up. Take care not to cross
thread the bolts.

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31. If using the included Side Force Generators or racing tips or both now is the time
to mount them. They are secured with 2 3mm bolts threaded into the blind nuts in
the wing tips.
32. Secure your flight batteries with heavy duty Velcro straps. I have had great
success using the Velcro brand One Wrap product.