Extreme Flight ARF RC User manual

106” Edge 540 V2 Assembly Manual
Thank you for purchasing this 3DHobbyShop by Extreme Flight ARF RC aircraft. If you have any
issues, questions, concerns or problems during assembly, please contact our tech department at:
[email protected] or 770-887-1794 10am-5pm Eastern Monday thru Friday.
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
set-up or have questions regarding servo choices, please contact us at [email protected] or
770-887-1794. It is your responsibility to ensure the airworthiness of your model.
SAFETY in Assembly
During assembly of this aircraft, you will be asked to use sharp knives and hobby adhesives.
Please follow all safety procedures recommended by the manufacturers of the products you use,
and always follow these important guidelines:
ALWAYS protect your eyes when working with adhesives, knives, or tools, especially power
tools. Safety glasses are the best way to protect your eyes.
ALWAYS protect your body, especially your hands and fingers when using adhesives, knives,
or tools, especially power tools. Do not cut toward exposed skin with hobby knives. Do not
place hobby knives on tables or benches where they can roll off or be knocked off.
ALWAYS have a first-aid kit handy when working with adhesives, knives, or tools, especially
power tools. ALWAYS keep hobby equipment and supplies out of the reach of children.

106” Edge 540 V2 Assembly Manual
Thank you for purchasing this 3DHobbyShop by Extreme Flight ARF RC aircraft. If you have any
issues, questions, concerns or problems during assembly, please contact our tech department at:
[email protected] or 770-887-1794 10am-5pm Eastern Monday thru Friday.
SAFETY in Flying
This is NOT a toy! It is a very high-performance RC airplane capable of high speeds and
extreme maneuvers. It should only be operated by a competent pilot in a safe area with proper
supervision.
•ONLY fly your aircraft in a safe, open area, away from spectators and vehicles and
where it is legal to fly. NEVER fly over an unsafe area, such as a road or street.
•NEVER fly near overhead power or utility lines. If your airplane ever becomes stuck
in a line or a tree DO NOT attempt to retrieve it yourself. Contact the authorities for
assistance in retrieving your aircraft. Power lines are DANGEROUS and falls from
ladders and trees CAN KILL!
•Never fly too close to yourself or spectators.
•Spinning propellers are DANGEROUS!
Never run your motor inside a house or building with the propeller attached Remove
the prop for safety. Always fly within your control.
•Always follow manufacturers instructions for your radio system.
•Always preform a pre-flight check of your aircraft to be certain of the aircraft's
airworthiness.
Always obtain proper insurance before flying. Always fly model aircraft in accordance with
the Academy of Model Aeronautics (AMA) Safety Code. Visit the AMA's website at
www.modelaircraft.org for more information.
Limits of Responsibility
Extreme Flight provides high-quality aircraft and components to it's
customers and end users. These aircraft and components are assembled
by the end user to produce a flying model. It is beyond Extreme Flight's
control to monitor the end user's completed aircraft. Therefore, Extreme
Flight in no way accepts or assumes responsibility or liability for damages
resulting from the end user assembled product. The end user assumes all
responsibility and liability in use of Extreme Flight aircraft and components
and agreeing to hold harmless Extreme Flight, it's distributors and dealers.

Assembly Instructions – Read completely before starting assembly!
UNPACK :
Unpack your airplane and examine the components. Check for damage of any kind. If you have
damage, please contact Extreme Flight to discuss. Contact info listed above.
WRINKLES :
Your airplane was packed in plastic at the factory without any wrinkles in the covering. You may
notice some wrinkles now; more likely, you will notice a few in a day or two or the first time you
take the plane out to the flying field. These wrinkles are the result of wood shrinkage and/or
expansion. Balsa wood changes size and shape slightly as it is exposed to varying humidity in the air.
This is a natural property of balsa wood. As your airplane adjusts to the weather in your part of the
world, wrinkles may appear and disappear. Wrinkles may be removed with the gentle application of
heat to the covering material on your airplane. The best tools to use are a heat gun and covering iron.
Apply the heat gently: the covering material will shrink as you apply the heat, and this will remove
the wrinkles. BE CAREFUL! Too much heat applied too quickly can damage the covering, either by
causing it to pull away from the wood at seams and corners or even by melting it. The covering will
shrink at low temperature with patient application of heat. Wrinkles in the covering DO NOT affect
flight performance. If you must shrink on a color-seam, use the iron and go slowly and carefully to
avoid any pulling or lifting at the seam.
Remove the canopy before attempting to use heat on your covering! The canopy is made of thermo-
activated plastic and WILL deform with the application of heat. Do not apply heat to the canopy.
PAINT:
If you need to clean your airplane, we recommend using a damp towel. The paint used on the canopy
and cowl is not safe for all cleaners. In particular, DO NOT use alcohol on these parts, it will remove
the paint.

Items needed for completion:
•Masking or painters tape
•Hobby knife with #11 blades.
•Fresh 30 minute epoxy. Pacer Z-Poxy has worked very well for us for many years.
•Blue and Red Loctite.
•Electric drill with an assortment of small drill bits.
•Small flat head and Phillips head screw drivers.
•Standard and needle nose pliers.
•Side cutters.
•Metric ball driver or allen key set. (especially 2.5 and 4mm drivers)
•Sanding block and sandpaper.
•Extreme Flight Servo Mounting Screws
•7 400oz (min) torque metal gear servos. (8 servos if you use 2 rudder servos)
•1 x standard size servo for the throttle.
•4 x Extreme Flight 1.5” single aluminum Servo Arms for the ailerons (tapped M3)
•2 x Extreme Flight 2” single aluminum arms for the elevators (tapped M3)
•1 x Extreme Flight 4” double offset aluminum arm for the rudder (tapped M3)
•2 x Extreme Flight 2-wire MPX Multi Plug (an quick and easy way to hook up wing servos)
•3 X 24" Extreme Flight 20 AWG Servo Extensions (2 outboard ailerons 1 for throttle).
•2 x 48” Extreme Flight 20 AWG Servo Extensions elevators and rear mounted rudder servo.
•5” Spinner
•100-120cc gas engine and recommended prop.
•Blazing Star DA 120cc engine mount
•Some type of engine mufflers (stock, canisters or tuned pipes and headers) Receiver, batteries,
switches, EF Flowmaster 34 ounce fuel tank and tubing, EF Fuel Dot.
1. Before starting assembly, take a few minutes to read the entire instruction manual to familiarize yourself with
the assembly process.
2. 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 CA to high stress areas such as servo mounting trays, landing gear mounts, anti-rotation pins, wing and
stab root ribs, and motor box joints etc.
4. 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.
5. Use high quality, fresh epoxy for installing the composite control horns and hinges. We highly recommend
Pacer Z-Poxy 30 minute Epoxy. We are very pleased with the results and ease of application and cleanup of
these products.
6. Take the time to properly balance and trim your aircraft and set up rates with exponential values. Your flying
experience will be greatly enhanced once your plane is properly dialed in.
7. Extreme Flight now has their own Vimeo channel. There are many assembly videos providing extreme detail
on certain aspects of the assembly.

Let’s get started!
1. Locate the wing panels/ailerons and horizontal stabilizers/elevators and associated hardware bags.
We will begin by hinging all of these at one time. I strongly recommend 30 minute (or slower curing)
epoxy for installing hinges. I have found it easier to apply 3-5 drops of glue in the hinge hole and then
using a toothpick, or similar, spread the glue around the sides of the hinge hole. Do this on just one
side, either the wing or aileron it does not matter which is first. Mix only enough glue to work with one
panel at a time. Before applying any glue to the hinge itself, I highly recommend you protect the hinge
pin (pivot point) from glue. I use Vaseline. Tape will work however it is harder to remove later. In any
case apply either protectant to the center of the hinge so glue cannot penetrate the pin which may cause
binding. Once you have the holes lathered with glue, apply a small amount to the hinge barbs and
insert into the hinge hole until the pin is even with the hinge line. Be sure your hinge pivots freely and
is perpendicular to the hinge line. Allow to dry then mate to the appropriate surface (wing to aileron/
horizontal stabilizer to elevator) and allow to dry.
***PLEASE NOTE*** there are 3 hinges that have been shortened to clear the tube socket. They are
glued into the 3 inboard positions as shown.

2. Install the control horns for the ailerons. ***PLEASE NOTE*** There are three DIFFERENT control
horns for the ailerons. The 106" Edge construction allows for three aileron servos per wing. Each control
horn is drilled different for pushrod attachment. This is to keep control horn/pushrod geomentry
consistent with all two or three servo positions. See the picture below for reference. The inboard control
horn hole is the lowest on the horn. The outboard is the highest on the horn. If using two aileron servos
per wing, use the inboard and outboard servo positions. Pay very close attention when separating and
grouping the horns to be sure you are gluing the correct horns in the correct location!.
Insert the horns into the base plate and then temporarily install them in the aileron. Trace around the base
plate with a fine tipped felt marker and then remove the horn and base plate. Use a sharp hobby knife to cut
2mm inside the line you marked and remove the covering. Scuff the bottom portion of the control horn that
inserts into the hole of the control surface and the bottom of the alignment plate. Use epoxy to secure the
control horns in place.

3. Install the aileron servos and orient the output shaft of the servo towards the leading edge of the wing.
We are using the Extreme Flight 1.5 inch servo arms for the ailerons. You will notice there are two types
of ball links included: one standard ball link and one with a built in riser. The standard ball link is
sandwiched between the control horns, the ball link with the riser is secured to the aluminum servo arm.
Thread the ball links onto each end of the turnbuckle pushrod. To secure the ball link to the control
horns insert the 3mm bolt with integrated washer thru the control horn, then the ball link in the middle,
then thru the other control horn, then the washer and nylon insert nut onto the other side. It is good
practice to determine the pushrod length for one servo and match the other three to this length.
Electronically center your servo and install the aluminum arm perpendicular to the servo case. Secure
the ball link with the riser to the servo arm. Do the same for the other servo locations. You will need to
use the servo matching function in your radio or an external device to make sure the two aileron servos
are perfectly synchronized and causing no binding. Failure to do so can destroy your servos in short
order.
4. Install the elevator servos, orient the output shaft toward the leading edge of the horizontal stabilizer.
It will be easier to install the servo arms after mounting the servo. Make all hookups for the pushrods/
ball links as we did in the previous step. Again, it is good practice to make the pushrods the same
length. I recommend using the 1.75" location on the 2 inch servo arm to maximize mechanical
advantage and minimize the chance of flutter.

5. Rudder installation. The 106" Edge includes hinges and hinge rod to make the rudder removable. Be sure
to take your time installing the hinges. Dry fit everything first! Be sure to orient the hinges consistently on
each side/surface. Dry fit the hinges and install the hinge rod. Adjust hinge slots as necessary. Once
satisfied with hinge fit and placement, apply glue to hinge slots. Using a zip tie end to guide the glue in the
slots. Apply more glue to the hinge and insert. Do this for both the rudder and the vertical stabilizer. Clean
up the excessive glue before install hinge rod. Mate the rudder to the vertical stabilizer with the hinge rod
and adjust as necessary. Once satisfied, tape the rudder in place to dry. Checking frequently to clean up
excess glue. Move the hinge rod and clean excess glue to allow the hinges to move freely. The hinge rod is
held in place by a wheel collar installed at the bottom of the rod.

For most installations a single ultra high torque servo mounted in the pull-pull position will be the ideal
way to power the rudder. We highly recommend the MKS HBL380 or 599 for this location. A double 4
inch Extreme Flight aluminum servo arm will provide plenty of travel while maintaining the best
mechanical advantage and servo resolution. Two control horns are provided for the rudder. The slots for
these must be located and opened with a sharp hobby knife. Install the control horns using the same
technique as the ailerons and elevators. Please reference the above photos of this setup for detail.
Locate the slots for the pull-pull wires to exit the rear of the fuselage. Open these slots with a hot soldering
iron. Install the pull-pull wires through the fuselage. The wires should run clear to the servo position.
Note: the pull-pull wires should cross inside the fuselage.

Install the rudder servo and center the double servo arm. Assemble the ball links and the pull-wire ends as
shown. Thread the pull-wire end in the ball links four to five turns. This will allow room to tighten the wires
after pull-pull wire installation is complete. Start at the rudder servo first. Thread the crimp sleeve on the wire
first, then through the pull-wire end. Back through the crimp sleeve. Allow enough wire through the sleeve to
loop back through the sleeve a third time. Once satisfied with the wire position, crimp the sleeve with a
needle-nose pliers. After the wires are attached to the rudder servo, tape the rudder in the neutral position.
Use the same technique to attach the pull-pull wires to the rudder. Take as much slack out of the wires as
possible before crimping the sleeves. Screw the pull-wire ends in to the ball links to take up the remainder of
the slack. Note: you want the pull-pull wires to be taught but not "banjo string" tight. They should not sag at
neutral position. After a few flights, recheck.

6. Next we will install the main landing gear, axles, tires, wheel pants and wheel cuffs. Use the
provided bolts, washers and nuts from the main landing gear hardware kit to mount the
carbon gear to the fuselage.
7. Install the landing gear plate cover over the mounting nuts. Glue in place with Goop style silicon
glue. Slide the landing gear cuffs into place against the fuselage and secure with Goop style silicon
glue. Tape in place until glue is fully cured.
8. Insert the axles into the holes on the landing gear leg and secure with a washer and lock nut.
Grind a flat spot on the axles to fasten the set screw against providing a better grip. Now install
one wheel collar, the wheel then the other wheel collar but do not tighten. Now position the
wheel pant onto the axle and determine the exact position of the inner and outer wheel collars
such that the tire will not rub against the wheel pant. Once you have this location add blue thread
lock to the set screw and tighten your wheel collars. Now position the wheel pant(s) onto the
axle/gear and secure with the 3mm bolts/washers and use blue thread lock on these as well.

9. Next we will install the tailwheel. Locate the tailwheel hardware bag. Notice the included ball link. This
will be installed in the bottom of the rudder for the tiller wire. It is good practice to remove all the set screws
and bolts in the tailwheel assembly and reassemble using blue Loctite. On the bottom of the rudder,
measure three inches from the hinge line. Make a mark to drill a 3/16 inch hole in the bottom of the rudder.
Mount the tailwheel assembly using the three M3 cap bolts and washers in the pre-installed blind nuts in the
fuselage. Be sure to use blue Loctite on the bolts. Glue the ball link in the rudder with epoxy, using the tiller
wire as a guide for depth.

10. Next we'll install the engine. There are laser marked locations to drill if using the DA-120. There is
also a laser scribed cross to use a template for other engine makes. Drill for 1/4x20 mounting bolts at the
proper locations.
11. Install the DA-120 using the Blazing Star one inch mount with BOTH 2mm and 3mm Delrin spacer
provided with the mount. Be sure the spacer goes between the mount and plywood firewall, not against the
engine. Secure using 1/4x20 bolts, washers and lock nuts (not included). Total distance from the front of the
motor box to the rear of the spinner backplate is 7 7/16" or 189mm.

12. The throttle servo is mounted to the bottom of the motorbox in the cutouts provided. Use a rotary tool
the open the bottom of the cowl to fit the mufflers and to provide an exit for air. A pipe tunnel is provided
along with vent covers for the bottom of the fuselage.
13. Secure your choice of tank to the tank tray over the carbon wing tube with Velcro or cable ties. We used the
EF Flowmaster 34 ounce tank and fuel tubing along with an EF fuel dot.
14. Install the remainder of electronics and radio equipment.
15. Slide the wing tube into the fuselage and slide the wings onto the tube. Secure using two wing bolts and two
hairpins secured to the aluminum pin forward on the wing.
16. The prefinished canopy is secured by four M3 thumb screws
17. A set of SFG's and wing tips are included. They are secured with M3 cap bolts. Blind nuts are installed in
the wingtips for mounting. Use the SFG's as a guide to locate the blindnuts. Open the covering with a hot
soldering iron.

Control Surface Throws
High Rate:
Ailerons – 40-42 degrees
Elevator – 55-60 degrees
Rudder – Maximum throw available without
interference
High rate controls typically use 50-75% exponential
Low Rate:
Ailerons – 15 degrees
Elevator – 20 degrees
Rudder – 30 degrees
Center of Gravity
The preferred CG for this plane is at 5.5” back from the leading
measured at the wingtip. This is the recommended CG to start with and
can then be tuned for a specific style of flying.