Extreme Flight EDGE 540T EXP User manual

EDGE 540T EXP
Electric ARF
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Greetings and congratulations on your purchase of the Extreme Flight RC
Edge 540T EXP ARF.Loosely based on our favorite variant of the Edge, the
2 seat Edge 540T, we have taken numerous liberties with this design to
produce an aircraft that is both unique in appearance and flight ability. The
designation EXP does not belong to a full scale Edge, but stands for
Experimental Progressive. This name was chosen due to the fact that the
Edge 540T EXP incorporates several new forward thinking design and
aerodynamic concepts. Having spent several months in development, flight
testing and refinement, we are very excited about the end result of our quest.
The Edge 540T EXP incorporates carbon fiber and G10 composites into the
structure of the airframe, resulting in a lightweight, yet twist free structure
capable of handling extreme aerodynamic loads. Carbon and G10 are used in
high stress areas such as motor box support, landing gear mounting structure
and fuselage longerons to provide enormous strength and durability. A true
piece of carbon fiber art, the landing gear is airfoiled and has just enough
"give" to cushion those not so perfect landings. The removable wing panels
are mounted on a carbon fiber wing tube and are fastened to the fuselage with
nylon thumbscrews. The large canopy (which is retained by a spring loaded
hatch latch) has been moved forward to place the tallest portion of the aircraft
at the center of gravity, resulting in the best knife edge performance of any
aircraft we've flown to date. The airfoiled tail surfaces are built using a
unique geodetic construction technique which allows the use of less material
while creating a structure that is superior in strength and rigidity to typical
ARF construction methods. All control surfaces are pushrod driven with short
linkages and use ball links for slop free actuation with no binding. Optional
Side Force Generators are included and add to the already generous side area,
increasing yaw axis authority and adding stability in all angles of sideslip.
Expertly painted fiberglass cowl and wheel pants and 2 gorgeous high
visibility Ultracote color schemes add the finishing touches and make this an
airplane that you will be proud to show up at the flying field with. The
combination of these unique elements add up to an aircraft that pushes the
boundaries of modern aerobatic flight.
If repairs become necessary, the Ultracote colors used on the Edge 540T EXP
are as follows:
Red/black color scheme: True Red, Bright Yellow, Black
Red/white/blue color scheme: True Red, White, Deep Blue, Silver

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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.
3. Use a fresh bottle of thin CA with a fine glue tip when attaching the CA
hinges. This will ensure that the proper amount of CA wicks into the hinge
and surrounding balsa wood and creates a proper bond between the wood and
hinges. We are big fans of the Mercury line of adhesives as well as the glue
tips provided by them.
4. Apply a couple drops of CA to high stress areas such as anti-rotation pins,
landing gear mounts, servo trays and motor box joints and carbon support
mounts.
5. All of the G10 control horns are the same with the exception of the elevator
horn. Its base has been shortened to fit the depth of the elevator.
6. When applying decals, first clean the area where the decal will be applied
with alcohol. Mist the area lightly with Windex before applying the decal
which will allow you to properly position it, 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.
7. Take the time to properly balance and trim your aircraft and set up rates
and exponential values. Your flying experience will be greatly enhanced by
doing this.
Please note : The assembly of the Edge 540T EXP is
almost identical to the assembly process of the
previously released Extra 300 EXP. Most photos will
show the Extra component assembly. Only assembly
steps which differ will show the Edge.

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Items needed for completion
-masking tape
-Thin and medium CA. We highly recommend Mercury M5T thin and M100XF medium
formulas as well as the Mercury glue tips.
-30 minute epoxy. I have used Pacer Z-Poxy for many years and it is a terrific product. It
cures in the allotted time and forms a permanent bond.
-Blue Loctite.
-Silicon based glue (Zap-A-Dap-A-Goo, etc.)
-Electric drill with an assortment of small drill bits.
-Small flat head and Phillips head screw drivers.
-Standard and needle nose pliers.
-Metric balldriver or allen key set.
-4 sub micro metal geared servos. All flight testing was performed with Hitec HS-65MG
and HS-5065MG digital servos and we strongly recommend the use of either of these high
quality servos.
-Torque 2814T/820 Brushless Outrunner motor.
-Airboss Elite 45 Amp ESC.
-4S 2100-2700 mah LiPo battery. We've had great success with the Zippy Rhino bargain
LiPos available from www.hobbycity.com in both 2200 mah and 2350 mah sizes.
-APC 12x6 E prop (NOT the slow fly version!).
-52mm Extreme Flight spinner.
-2 18"-24" extensions for the 2 rear servos and 2 6"-8" extensions to go between the
receiver and the aileron servo leads. We recommend the 28 or 32 AWG extensions to save
weight.
-Adhesive backed Velcro and Velcro strap for battery retention.

Let's begin!
1. So that we don't have to wait for the 30 minute epoxy to dry in a later step,
let's go ahead and prepare the 4 carbon fiber pushrods and ball links for later
use. Locate the 4 carbon fiber pushrods and 4 micro ball links in the
hardware package. Lightly scuff one end of each pushrod.
2. Mix up a small batch of 30 minute epoxy. Dip the scuffed end of each
pushrod into the epoxy and insert this end into the ball link with a twisting
motion to make sure the epoxy is evenly distributed inside the ball link. Make
sure the pushrod is completely inserted into the ball link.
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3. Use a paper towel to wipe away most of the excess epoxy, leaving a small
fillet between the carbon pushrod and ball link. Position the pushrods
vertically while they cure as illustrated so the fillet remains in position. DO
NOT use CA for this bond!
4. Locate the 2 wing panels with ailerons as well as the 2 G10 aileron control
horns. Remove the ailerons from the wing and remove the covering over the
slot for the aileron horn on the bottom of the aileron with a sharp hobby
blade. Make sure you are doing this on the bottom of the aileron!
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5. Scuff the portion of the control horn that will be glued into the aileron with
sandpaper.
6. Use a glue tip on your bottle of medium CA and apply glue to the slot as
well as to both sides of the control horn. Insert the control horn into the slot
and make sure it seats properly against the surface of the aileron.
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7. Remove the covering from the aileron servo location and make sure the
hinges are centered in their slots.
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8. Slide the aileron into position on the hinges and secure with several drops
of fresh thin CA. This process is much easier and more effective if a fine glue
tip is used. Make sure to deflect the surface as pictured while applying the
CA.
9. Use the screws provided by the servo manufacturer to secure the aileron
servo in the designated location. 1 screw installed in the center hole at each
end of the servo is adequate to secure the servo. Make sure the output shaft is
positioned toward the trailing edge of the wing.
10. Use a 5/64" drill bit to enlarge the outermost hole in the nylon servo arm
that is provided with the servo. Use the longest arm included. Locate one of
the EZ connectors and insert the shaft of the connector into the 5/64" hole. A
drop of oil placed on the shaft of the connector will ensure that it moves freely
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within the hole. Place the retaining nut on the threaded portion of the
connector shaft and screw down until tight, then back off the nut just enough
to allow the connector to turn freely. Place a single drop of CA on the end of
the threaded shaft to prevent the nut from coming off.
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11. Two of the carbon pushrod/ball link assemblies are the same size. These
are the aileron pushrods. In addition locate 2 silver 2 mm screws, washers
and nuts from the hardware package. Secure the ball link side of the pushrod
to the aileron control horn on the side of the horn that will be closest to the
fuselage by inserting a 2mm bolt into a washer, then through the hole in the
brass ball and finally through the hole in the G10 control horn. Place a
washer onto the screw and secure with a 2mm nut. Be sure to use a drop of
blue Loctite to prevent the nut from backing off of the screw. Electronically
center your servo and attach the servo arm with the EZ connector that you
pre-fabricated in a previous step. Insert the carbon pushrod into the hole in
the EZ connector. This process is probably better explained in the following
series of pictures.
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12. Secure the carbon pushrod to the EZ connector with the provided set
screw. Take care not to over tighten the set screw and crush the carbon rod.
Once you feel the set screw engage the carbon pushrod another 3/4 to 1 turn
will supply adequate pressure to retain the pushrod. Make sure that the servo
arm is perpendicular to the servo case when the aileron is in the neutral
position.
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Here is a photo of the completed installation.
Repeat this process for the other wing half.
13. Locate the fuselage, one piece carbon fiber landing gear, 2 silver 3mm
machine screws and 2 washers. Secure the landing gear to the fuselage by
inserting a 3mm screw into a washer, through the carbon fiber gear and into
the pre-installed blind nut in the fuselage. Make sure to use a drop of blue
Loctite on each screw to prevent them from backing out.
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14. Locate the 2 axles, 2 locking nuts, 2 wheels, 2 wheel collars and 2 wheel
pants from the hardware package. Place the wheel onto the axle and secure
with a wheel collar. Place the threaded portion of the axle through the hole in
the carbon gear and screw the lock nut onto the axle, but do not tighten
completely. There is a slot pre-cut in the wheel pant to allow it to fit over the
axle. Before installing the wheel pant place a drop of silicon based glue onto
the wheel pant just above the pre-cut slot. This will prevent the wheel pant
from rotating, but allow it to move in the case of a mishap which may help to
prevent damage. Slide the wheel pant into position over the axle and tighten
the nut on the axle, taking care to make sure the wheel pant is positioned
properly. Repeat this process for the remaining wheel pant. Again this is
probably better explained in the following series of pictures.
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15. Locate the horizontal stabilizer/elevator assembly and slide the elevator
off of the hinges. Insert the stabilizer into its slot and the carbon fiber wing
tube into the fiberglass sleeve. Use a ruler to insure that the stabilizer is
centered in its slot and compare the stabilizer to the wing tube to make sure it
is properly aligned. Sand or shim the slot if necessary to ensure proper
alignment. Secure the stabilizer with CA.
16. Remove the covering over the right slot on the bottom of the elevator
where the elevator control horn will be installed. The elevator horn is the one
with the shortest shank that is glued into the surface. Scuff the portion of the
control horn that will insert into the elevator with sandpaper. Secure the
control horn with medium CA.
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17. Slide the elevator onto the hinges in the stabilizer and secure with thin
CA. Again a fresh bottle of CA and a fine glue tip work best here.
18. Remove the covering over the slot in the lower right side of the rudder
where the rudder control horn will be installed. Scuff the portion of the
control horn that will glue into the surface and secure the rudder control horn
with medium CA.
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19. Using the same process as with the ailerons and elevator, slide the rudder
onto the hinges and secure to the vertical stabilizer with thin CA.
20. Locate the carbon fiber tailwheel assembly in the hardware package.
Secure the tailwheel bracket to the bottom rear of the fuselage with the
provided wood screws. Make sure the pivot point of the assembly is over the
hinge line of the rudder for best results.
21. Secure the tiller using the provided screw, but do not over tighten as the
tiller should be able to move on the screw as the rudder is deflected.
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22. Place the tailwheel wire in the proper position, aligned with the rudder
and lock into place with the 2 set screws.
23. Use the hardware provided with the servos to install the rudder and
elevator servos in their respective location in the rear of the aircraft. From
the pilot's perspective the rudder servo mounts on the right side of the
fuselage and the elevator servo mounts on the left side. The elevator servo
should have the output shaft toward the rear of the aircraft while the rudder
servo output shaft should be toward the front of the aircraft.
24. The rudder and elevator servo linkage assembles and is installed just like
the aileron linkage. For maximum elevator travel we have included a G10
control horn which is bolted to the stock control horn provided with the servo.
We have found it easiest to tack glue the G10 arm to the nylon arm and then
using the holes in the nylon arm as a guide, drill through the composite arm.
Secure the arm with the provided screws and bolts. The remaining portion of
the linkage installation is the same as the other control surfaces.
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25. Mount the motor using the supplied 3mm black socket head cap bolts
which are threaded into the blind nuts which are pre-installed in the motor
mount plate. Be sure to put a drop of blue Loctite onto each bolt to prevent
them from backing out. Be sure to add some CA to all motor box joints as
well as to the attachment points of the carbon fiber motor box supports.
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