GREAT PLANES EDGE 540 T Performance Series User manual

INSTRUCTION MANUAL
Wingspan: 49.5 in [1260mm]
Wing Area: 490 in2[31.6dm2]
Weight: 3.25 – 3.5 lb [1470 – 1590g]
Wing Loading: 15.0 – 16.0 oz/ft2[46 – 49g/dm2]
Length: 48 in [1220mm]
Radio: 4-channel minimum, 5-channel computer radio with
mixing capabilities (for separate ailerons)
Motor: RimFire™42-50-800 out-runner
READTHROUGHTHIS MANUAL BEFORE STARTING CONSTRUCTION.IT CONTAINS IMPORTANT INSTRUCTIONS
ANDWARNINGS CONCERNING THE ASSEMBLY AND USE OFTHIS MODEL.
Champaign, Illinois
[phone], Ext 5
airsuppor[email protected]
Entire Contents © Copyright 2008 GPMA1572MNL V1.0
Great Planes®Model Manufacturing Co. guarantees this kit to be
free from defects in both material and workmanship at the date
of purchase. This warranty does not cover any component parts
damaged by use or modification. In no case shall Great Planes’
liability exceed the original cost of the purchased kit. Further,
Great Planes reserves the right to change or modify this warranty
without notice.
In that Great Planes has no control over the final assembly or
material used for final assembly, no liability shall be assumed nor
accepted for any damage resulting from the use by the user of
the final user-assembled product. By the act of using the user-
assembled product, the user accepts all resulting liability.
If the buyer is not prepared to accept the liability associated
with the use of this product,the buyer is advised to return this
kit immediately in new and unused condition to the place of
purchase.
To make a warranty claim send the defective part or item to Hobby
Services at the address below:
Hobby Services
3002 N. Apollo Dr., Suite 1
Champaign, IL 61822 USA
Include a letter stating your name, return shipping address, as
much contact information as possible (daytime telephone number,
fax number, e-mail address), a detailed description of the problem
and a photocopy of the purchase receipt. Upon receipt of the
package the problem will be evaluated as quickly as possible.
WARRANTY

2
TABLE OF CONTENTS
INTRODUCTION...............................................................2
AMA ..................................................................................2
SAFETY PRECAUTIONS .................................................3
DECISIONSYOU MUST MAKE........................................3
Radio Equipment..........................................................3
Transmitter ...................................................................3
Receiver.......................................................................3
Servos..........................................................................3
Connectors...................................................................3
Motor Recommendations.............................................4
ESC (electronic speed control) ....................................4
Flight Battery................................................................4
ADDITIONAL ITEMS REQUIRED ....................................4
Required Adhesives & Building Supplies.....................4
Optional Supplies & Tools ............................................4
IMPORTANT BUILDING NOTES......................................4
ORDERING REPLACEMENT PARTS..............................5
KIT INSPECTION..............................................................6
KIT CONTENTS................................................................6
PREPARATIONS...............................................................7
ASSEMBLETHE WINGS..................................................7
Install the Aileron Servo & Pushrods............................8
ASSEMBLETHE FUSELAGE ..........................................8
Install the Main Landing Gear......................................9
Install the Tail Gear.....................................................10
Install the Stabilizer....................................................11
Install the Elevators Hinges........................................12
Install the Elevators....................................................12
Install the Motor..........................................................12
INSTALLTHE RADIO SYSTEM .....................................12
Install the Elevator Servo ...........................................12
Install the Rudder Servo.............................................13
Rudder Pull-Pull Installation.......................................13
Rudder Servo Installation in the Tail...........................15
Apply the Decals........................................................16
GETTHE MODEL READYTO FLY.................................16
Check the Control Directions .....................................16
Set the Control Throws...............................................17
FINISHTHE MODEL.......................................................18
Balance the Model (C.G.)...........................................18
Balance the Model Laterally.......................................19
PREFLIGHT....................................................................19
IdentifyYour Model.....................................................19
Charge the Batteries..................................................19
Balance Propellers.....................................................19
Range Check .............................................................19
MOTOR SAFETY PRECAUTIONS .................................19
AMA SAFETY CODE (EXCERPTS)...............................20
CHECK LIST...................................................................20
FLYING............................................................................21
Takeoff........................................................................21
Flight ..........................................................................21
Landing ......................................................................22
3D FLYING......................................................................22
INTRODUCTION
The full-scale Zivko Edge 540T is a great two seat, competition
aerobatic trainer. Great Planes has taken the best qualities of
the full-scale Edge 540T and reduced it down to a lightweight,
50" electric powered ARF. The Great Planes Edge 540T EP
ARF flies much like the giant-size Edge’s, but in a much less
expensive package.Now you canpractice forIMACcompetition
without risking your larger, more expensive planes.
For the latest technical updates or manual corrections to
the Edge 540T EP ARF visit the Great Planes web site at
www.greatplanes.com. Open the “Airplanes” link, then
select the “Edge 540T EP” ARF. If there is new technical
information or changes to this model a “tech notice” box will
appear in the upper left corner of the page.
AMA
WeurgeyoutojointheAMA(AcademyofModelAeronautics)
andalocalR/Cclub.The AMAisthegoverningbodyofmodel
aviation and membership is required to fly at AMA clubs.
Though joining the AMA provides many benefits, one of the
primary reasons to join is liability protection.Coverage is not
limited to flying at contests or on the club field.It even applies
to flying at public demonstrations and air shows. Failure to
comply with the Safety Code (excerpts printed in the back of
the manual) may endanger insurance coverage.Additionally,
training programs and instructors are available at AMA club
sites to help you get started the right way. There are over
2,500 AMA chartered clubs across the country. Contact the
AMA at the address or toll-free phone number below.
Academy of Model Aeronautics
5151 East Memorial Drive
Muncie, IN 47302-9252
Tele. [phone]
Fax [phone]
Or via the Internet at:
http://www.modelaircraft.org
IMPORTANT!!! Two of the most important things you can do
to preserve the radio controlled aircraft hobby are to avoid
flying near full-scale aircraft and avoid flying near or over
groups of people.

3
PROTECTYOUR MODEL,YOURSELF
& OTHERS....FOLLOWTHESE
IMPORTANT SAFETY PRECAUTIONS
1.Your Edge 540T EP ARF should not be considered a toy,
but rather a sophisticated, working model that functions very
much like a full-size airplane. Because of its performance
capabilities, the Edge 540T EP ARF, if not assembled and
operated correctly, could possibly cause injury to yourself or
spectators and damage to property.
2.Youmustassemblethemodelaccordingtotheinstructions.
Do not alter or modify the model, as doing so may result in an
unsafe or unflyable model.In a few cases the instructions may
differ slightly from the photos. In those instances the written
instructions should be considered as correct.
3.You must take time to build straight, true and strong.
4. You must use an R/C radio system that is in first-class
condition, and a correctly sized motor and components
(wheels, etc.) throughout the building process.
5. You must correctly install all R/C and other components
so that the model operates correctly on the ground and in
the air.
6.You must check the operation of the model before every
flight to insure that all equipment is operating and that the
model has remained structurally sound. Be sure to check
clevises or other connectors often and replace them if they
show any signs of wear or fatigue.
7. If you are not an experienced pilot or have not flown
this type of model before, we recommend that you get the
assistance of an experienced pilot in your R/C club for
your first flights. If you’re not a member of a club, your local
hobby shop has information about clubs in your area whose
membership includes experienced pilots.
8. WARNING: The cowl and wheel pants included in this kit
are made of fiberglass, the fibers of which may cause eye,
skin and respiratory tract irritation. Never blow into a part
(wheel pant, cowl) to remove fiberglass dust, as the dust
will blow back into your eyes.Always wear safety goggles, a
particle mask and rubber gloves when grinding, drilling and
sanding fiberglass parts. Vacuum the parts and the work
area thoroughly after working with fiberglass parts.
We, as the kit manufacturer, provide you with a top quality,
thoroughly tested kit and instructions, but ultimately the
quality and flyability of your finished model depends
on how you build it; therefore, we cannot in any way
guarantee the performance of your completed model,
and no representations are expressed or implied as to the
performance or safety of your completed model.
Remember:Take your time and follow the instructions to
end up with a well-built model that is straight and true.
DECISIONSYOU MUST MAKE
This is a partial list of items required to finish the Edge 540T
EP ARF that may require planning or decision making before
starting to build.
Radio Equipment
A 4-channel radio system with four micro servos and micro
receiver are required for this plane.The servos and receiver
shown in the manual are Futaba®S3115 Micro Precision
Servo and the Futaba R146iP PCM receiver. For more
precision, the Futaba S3150 Slim Digital Servos work great.
Transmitter
❏4-channel radio (minimum)
or
❏5-channel computer radio with mixing capabilities
(for separate ailerons).
Receiver
❏Futaba 4 to 6 channel R146iP PCM receiver (FUTL0601)
❏Futaba FM Single Conversion Short Crystal (Low Band
(11 to 35) – FUTL62**, High Band (36 to 60) – FUTL63**)
Servos
❏(4) Futaba S3115 Micro Precision Servos (FUTM0415)
(38.9 oz-in [2.8 kg-cm] of torque)
or
❏(4) Futaba S3150 Slim Digital Servos (FUTM0303)
(51.4 oz-in [3.7 kg-cm] of torque)
For 3D rudder throws a 2" [50.8mm] double-sided servo arm
may be required (GPMM1155)
Connectors
❏(1) “Y” harness (FUTM4135)
❏(2) 16" extensions (FUTM3955)
❏(2) 12" extensions (HCAM2100)

4
Motor Recommendations
The Edge 540T EP ARF comes with a mounting box for the
Great Planes RimFire™brushless out-runner motor. The
motor has been tested with this plane and works well.
❏Great Planes RimFire 42-50-800 Brushless Out-runner
Motor (GPMG4700)
ESC (electronic speed control)
Abrushless ESC (electronic speed control) is requiredfor the
recommended motor set-up.We recommend using the Great
Planes Silver Series SS-45A Brushless ESC (GPMM1840).
If you will be using the 4S LiPo setup for 3D flying, a voltage
regulator must be used with this ESC.If a voltage regulator
is not used the ESC may be damaged.
Flight Battery
We recommend two different battery and prop setups
depending on the type of flying you prefer to do. For basic
sport flying we recommend the Great Planes Power Series™
LiPo 2100mAh 11.1V, 3200mAh 11.1V battery or Flight
Power 2170mAh 11.1V and 2500mAh 11.1V with an APC
13" x 8E propeller.
For all out 3D type flying we recommend the Great Planes
Power Series LiPo 2100mAh 14.8V or FlightPower 2170mAh
14.8V battery with an APC 12" x 6E propeller. A voltage
regulator will also be required to power the receiver.Be sure to
follow the ESC instructions for using a separate power source
(voltage regulator or receiver battery) for the receiver.
When charging the batteries we highly recommend using a
Great Planes Equinox™LiPo Cell Balancer (GPMM3160).
Sport Setup:
❏Great Planes Power Series LiPo 2100mAh 11.1V 20C
discharge w/balance plug (GPMP0617)
❏Great Planes Power Series LiPo 3200mAh 11.1V 20C
discharge w/balance plug (GPMP0623)
❏FlightPower EVO25 LiPo 2170mAh 11.1V
25C (FPWP0327)
❏FlightPower EVO25 LiPo 2500mAh 11.1V
25C (FPWP0333)
❏APC 13" x 8E Propeller (APCQ3080)
3D Setup:
❏Great Planes Power Series LiPo 2100mAh 14.8V 20C
discharge w/balance plug (GPMP0618)
❏FlightPower EVO25 LiPo 2170mAh 14.8V
25C (FPWP0328)
❏APC 12" x 6E Propeller (APCQ4130)
❏ElectriFly Voltage Regulator (GPMM1920)
❏Great Planes Parallel ESC Adapter Deans Ultra
Connector (GPMM3141)
ADDITIONAL ITEMS REQUIRED
Required Adhesives & Building Supplies
Thisisthelistofadhesivesandbuildingsuppliesrequiredtofinish
the Edge 540T EP.Order numbers are provided in parentheses.
❏1/2 oz. [15g] Thin Pro™CA (GPMR6001)
❏1/2 oz. [15g] Medium Pro CA+ (GPMR6007)
❏Pro 30-minute epoxy (GPMR6047)
❏Denatured alcohol (for epoxy clean up)
❏Drill bits: 1/16" [1.6mm], 3/32" [2.4mm], 9/64" [3.6mm],
5/32" [4mm], 7/32" [5.6mm],
❏#1 Hobby knife (HCAR0105)
❏#11 Blades (5-pack, HCAR0211)
❏Small T-pins (100, HCAR5100)
❏Non-elastic monofilament or Kevlar®fishing line
(for stabilizer alignment)
Optional Supplies &Tools
Here is a list of optional tools mentioned in the manual that
will help you build the Edge 540T EP ARF.
❏2 oz. [57g] Spray CA activator (GPMR6035)
❏CA applicator tips (HCAR3780)
❏CA debonder (GPMR6039)
❏Mixing sticks (50, GPMR8055)
❏Mixing cups (GPMR8056)
❏Threadlocker threadlocking cement (GPMR6060)
❏AccuThrow™Deflection Gauge (GPMR2405)
❏C.G. Machine™(GPMR2400)
❏21st Century®sealing iron [COCR2700]
❏21st Century iron cover [COVR2702]
IMPORTANT BUILDING NOTES
• There are two types of screws used in this kit:
• Sheet Metal Screws are designated by a number and
a length. For example 2 x 12mm.
The screw has a diameter of 2mm and a length of 12mm.
• Machine screws are designated by a number, threads
per inch, and a length. For example 4-40 x 3/4" [19mm]

5
This is a number four screw that is 3/4" [19mm] long
with forty threads per inch.
• Socket Head Cap Screws (SHCS) are designated by
a number, threads per inch, and a length. For example
4-40 x 3/4" [19mm].
This is a 4-40 SHCS that is 3/4" [19mm] long with forty
threads per inch.
• When you see the term test fit in the instructions,
it means that you should first position the part on the
assembly without using any glue, then slightly modify
or custom fit the part as necessary for the best fit.
• Whenever the term glue is written you should rely upon
your experience to decide what type of glue to use.When
a specific type of adhesive works best for that step, the
instructions will make a recommendation.
• We recommend 30-minute epoxy only, because you will
need the working time or the additional strength.
• Photos and sketches are placed before the step they
refer to. Frequently you can study photos in following
steps to get another view of the same parts.
• The Edge 540T EP ARF is factory-covered with Top
Flite®MonoKote®film. Should repairs ever be required,
MonoKote can be patched with additional MonoKote
purchased separately. MonoKote is packaged in six-foot
rolls, but some hobby shops also sell it by the foot. If
only a small piece of MonoKote is needed for a minor
patch, perhaps a fellow modeler would give you some.
MonoKote is applied with a model airplane covering iron,
but in an emergency a regular iron could be used. A roll
of MonoKote includes full instructions for application.
Following are the colors used on this model and order
numbers for six foot rolls.
White – TOPQ0204
Sapphire Blue – TOPQ0226
Medium Purple – TOPQ0225
Sky Blue – TOPQ0206
Royal Blue –TOPQ0221
ORDERING REPLACEMENT PARTS
Replacement parts for the Great Planes Edge 540T EP ARF
are available using the order numbers in the Replacement
Parts List that follows.The fastest, most economical service
can be provided by your hobby dealer or mail-order company.
To locate a hobby dealer, visit the Hobbico web site at www.
hobbico.com. Choose “Where to Buy” at the bottom of the
menu on the left side of the page. Follow the instructions
provided on the page to locate a U.S., Canadian or
International dealer.
Parts may also be ordered directly from Hobby Services by
calling [phone], or via facsimile at [phone],
but full retail prices and shipping and handling charges will
apply. Illinois and Nevada residents will also be charged
sales tax. If ordering via fax, include a Visa®or MasterCard®
number and expiration date for payment.
Mail parts orders and payments by personal check to:
Hobby Services
3002 N. Apollo Drive, Suite 1
Champaign, IL 61822
Be certain to specify the order number exactly as listed in
the Replacement Parts List. Payment by credit card or
personal check only;no C.O.D.
IfadditionalassistanceisrequiredforanyreasoncontactProduct
Support by e-mail at productsuppor[email protected],
or by telephone at [phone].
Replacement Parts List
Description How to Purchase
Missing pieces Contact Product Support
Instruction manual Contact Product Support
Full-size plans Not available
Contact your hobby supplier for the following parts:
GPMA3310 Wing Set
GPMA3311 Fuselage Set
GPMA3312 Tail Set
GPMA3313 Landing Gear
GPMA3314 Wheel Pants (2)
GPMA3315 Tail Wheel Assembly
GPMA3316 Cowl w/Cowl Ring
GPMA3317 Canopy Hatch
GPMA3318 Carbon Fiber Wing Tube
GPMA3321 Decal Sheet
GPMQ4404 10-24 Nylon EZ Bolts (2)
GPMQ4273 4mm Low Profile Landing Gear Axles (2)
Performance Upgrade Parts
GPMA3319 Carbon Fiber Landing Gear
GPMA3320 Carbon Fiber Wheel Pants (2)

6
KIT INSPECTION
KIT INSPECTION
Before starting to build, take an inventory of this kit to make sure it is complete and inspect the parts to make sure they
are of acceptable quality.If any parts are missing or are not of acceptable quality, or if you need assistance with assembly,
contact Product Support. When reporting defective or missing parts, use the part names exactly as they are written in
the Kit Contents list.
Great Planes Product Support:
3002 N Apollo Drive, Suite 1
Champaign, IL 61822
Telephone: [phone], ext. 5
Fax: [phone]
E-mail: [email protected]
Kit Contents
1 Cowl
2 Canopy
3 Fuselage
4 Spinner
5 Main Landing Gear (L&R)
6 Wheel Pants (L&R)
7 Main Wheels (2)
8 Tail Gear Assembly
9 Elevator Halves (L&R)
10 Horizontal Stabilizer
11 Right Wing Panel w/Aileron
12 Left Wing Panel w/Aileron
13 Carbon Fiber Wing Tube
KIT CONTENTS
KIT CONTENTS
3
48
12
9 9
10
55
6
77
1
2
11
13

7
PREPARATIONS
❏ 1.If you have not done so already, remove the major parts
of the kit from the box and inspect for damage. If any parts
are damaged or missing, contact Product Support at the
address or telephone number listed in the “Kit Inspection”
section on page 6.
❏ 2. Remove the tape and separate the elevators from the
stab. Use a covering iron with a covering sock on medium/
high heat to tighten the covering if necessary.Apply pressure
over sheeted areas to thoroughly bond the covering to the
wood. Caution: The Edge 540T EP was designed to be
strong where needed, but light weight for excellent flight
performance. Care must be taken when assembling the
plane to avoid damage.
ASSEMBLETHE WINGS
Install the Ailerons Servos & Pushrods
❏ ❏ 1. Inside the servo bay a string is taped. Carefully
remove the string from the servo bay and tape it to the
outside of the wing to prevent it from dropping back into the
wing.Test fit your aileron servo in the servo bay. Enlarge the
opening if required.
❏ ❏ 2.Install a 12" [305mm] servo extension onto the servo
lead. Secure the extension to the lead with tape, a piece of
heat-shrink tubing or some other method to keep them from
coming unplugged.
❏ ❏ 3.Tie the string to the servo extension.Pull the string and
the servo lead through the wing. Untie the string from the lead.
❏ ❏ 4.Install the servo into the servo opening.Drill through
the servo mounting holes with a 1/16" [1.6mm] drill bit.
Remove the servo from the servo opening. Install and then
remove a servo mounting screw into each of the holes you
have drilled.Apply a drop of thin CA into the holes to harden
the threads. Once the glue has cured install the servo into
the servo opening using the servo screws provided with the
servo and the 2 x 7 x 9mm servo retaining plates. If your
servo uses two screws at each end, do not use the retaining
plates. Center the servo and then install a servo arm as
shown.The arm should be pointing towards the wingtip.
❏ ❏ 5.Thread a nylon clevis, 20 turns, onto a 6" [152mm]
wire pushrod.
7

8
HINGE LINE
CORRECT INCORRECT
❏ ❏ 6.Cut the control horn and mounting plate apart.Attach
the clevis in the outer hole of a nylon control horn. Place the
control horn in line with the hole 3/4" [19mm] from the center
of the servo arm.When positioned properly the control horn
will rest on a hardwood plate in the aileron.Mark the location
of the mounting holes onto the aileron. Drill a 3/32" [2.4mm]
hole on the marks, drilling through the plywood plate and the
top of the aileron.
❏ ❏ 7. Insert two 2-56 x 5/8" [16mm] machine screws
through the control horn and aileron.Secure the control horn
to the aileron with the nylon control horn backplate.
❏ ❏ 8. Slide a silicone clevis retainer over the clevis. With
the aileron servo and the aileron centered, mark the aileron
pushrod where it crosses the aileron servo arm. Make a 90°
bend at the mark. Cut the pushrod 3/8" [9.5mm] past the
bend. Attach the pushrod to the aileron servo arm with a
nylon FasLink.
❏ ❏ 9. Glue the carbon fiber anti rotation pin in the hole as
shown.The pin should protrude approximately 1/4" [6.4mm].
❏ 10. Repeat steps 1 to 9 for the left wing panel.
ASSEMBLETHE FUSELAGE
Install the Main Landing Gear
❏ ❏ 1. Insert a 4mm axle through the right main landing
gear. Secure the axle to the landing gear with a 5mm flat
washer and 5mm lock nut. Note: The front of the main
landing gear sweeps forward.
❏ ❏ 2. Install two 5mm flat washers on the axle, then the
foam main wheel, followed by a 4.2mm wheel collar. Secure
the wheel collar on the axle with 6-32 set screw. Mark the
8

location where the set screw tightens on the axle and use a
metal cutting file to file a flat spot on the axle.Apply a drop of
threadlocker on the set screw and reinstall the wheel collar
on the axle.
❏ ❏ 3. Position the right wheel pant over the wheel and
secure it to the main landing gear with two 2-56 x 3/8" [9.5mm]
machine screws, 2mm flat washers and 2mm lock washers.
❏ ❏ 4. Attach the main landing gear to the fuselage with
three 4-40 x 1/2" [12.7mm] SHCS, 3mm lock washers and
3mm flat washers.
❏ 5. Repeat steps 1 to 4 for the left main landing gear.
Install theTail Gear
❏ 1. Glue the nylon tail gear bushing in the hole in the aft
bottom of the fuselage.
❏ 2. Insert the tail gear wire through the aluminum tail gear
bracket. Insert the tail gear wire and bracket in the tail gear
bushing. With the tail gear bracket aligned with the bottom
of the fuselage, mark and drill a 1/16" [1.6mm] pilot hole at
both tail gear bracket mounting hole locations. Secure the
tail gear bracket to the fuselage with two 2 x 12mm sheet
metal screws.
❏ 3. Thread a 4-40 set screw into the 2.5mm wheel collar.
Remove the tail gear wire from the tail gear bracket and
position the 2.5mm wheel collar under the bracket.Slide the
9

10
nylon tail gear post onto the thin tail gear wire. Insert the tail
gear wire through the aluminum tail gear bracket and wheel
collar while inserting the tail gear post in the bottom of the
rudder.Tighten the set screw in the wheel collar and glue the
tail gear post in the rudder with thin CA.
❏ 4. Install the tail wheel on the tail gear wire and press the
silicone retainer on the tail gear wire to secure the tail wheel.
Install the Stabilizer
❏ 1. Center the wing tube in the fuselage. Slide the wing
halves onto the wing tube and secure the wing halves to
the fuselage with the nylon 10-24 thumb screws. Be careful
putting pressure on the wing and fuselage. The wings may
be tight the first time they are slid on the tube.
❏ 2.Centerthehorizontalstabilizerintheslotinthefuselage.
Stand back and look at the stab in relation to the wing.The
stab should be parallel with the wing. If not, sand the stab
saddle until the stab and wings are aligned.
❏ 3. Measure the distance from the tip of the stab to the
center of the fuselage. Adjust the position of the stab until
they are equal. The stringer is centered in the front of the
fuselage.
❏ 4. Using a fine-point felt-tip pen, mark the outline of the
fuselage on the top and the bottom of the stab.
❏ 5. Cut the covering on the top and bottom of the stab
inside the line you have drawn. Use care to cut only into the
covering and not into the wood.

11
HOWTO CUT COVERING FROM BALSA
Use a soldering iron to cut the covering from the area
beneath the wing bolt plate.The tip of the soldering iron
doesn’t have to be sharp, but a fine tip does work best.
Allow the iron to heat fully.
Use a straightedge to guide the soldering iron at a rate
that will just melt the covering and not burn into the wood.
The hotter the soldering iron, the faster it must travel to
melt a fine cut. Peel off the covering.
❏ 6. Wipe away the lines you drew. Insert the elevator
joiner wire in the notch at the back of the stab saddle.
Use epoxy to glue the stab in place, being careful that the
stab is properly aligned.
Tip: Place a piece of masking tape on the top and bottom of
the stabilizer, just outside the cut covering.Insert the stab in
the fuselage so that part of the bare wood is showing.Apply
30-minute epoxy to the wood, top and bottom.Slide the stab
through the fuselage so that approximately 1/2" [12.7mm]
of bare wood is showing on the other side and apply epoxy
to the wood. Now align the stab, remove the masking tape
and wipe off any excess epoxy from the stab and fuselage.
Recheck that the stab is still aligned.
You can now remove the wings and continue with the
assembly of the fuselage.
Install the Elevator Hinges
❏ ❏ 1.Drill a 3/32" [2.4mm] hole, 1/2" [12.7mm] deep in the
center of each hinge slot to allow the CA to “wick” in.Follow-
up with a #11 blade to clean out the slots. Hint: If you have
one, use a high-speed rotary tool to drill the holes.
❏ ❏ 2.Use a sharp #11 blade to cut a strip of covering from
the hinge slots in the wing and aileron.
Trim the Corners
1" [25mm] 3/4" [19mm]
❏ ❏ 3. Cut six 3/4" x 1" [19 x 25mm] hinges from a CA
hinge strip. Snip off the corners so they go in easier. Insert
three hinges in each elevator.

12
❏ ❏ 4.Test fit the elevators to the stab with the hinges.If the
hinges don’t remain centered, stick a pin through the middle
of the hinge to hold it in position.
Install the Elevators
❏ 1. Install the elevators onto the stab with the elevator
joiner wire in each elevator half. Check that both elevator
halves are aligned. If not, remove the elevators and while
holding one leg of the elevator joiner wire, slightly bend the
other. Reinstall the elevator halves and check again.
❏ 2.Coat the inside of the two elevator joiner wire holes and
the ends of the elevator joiner wire with epoxy.Install the two
elevator halves, remove the pins and glue the hinges with
thin CA.
Install the Motor
The Edge 540T EP has been designed to use the Great
Planes RimFire 42-50-800 Out-runner Brushless motor.
If you will be installing a different motor, you may need to
modify the plywood motor box.
❏ 1.InstalltheRimFiremotorusingfour4-40x1/2"[12.7mm]
SHCS, four 3mm lock washers and four 3mm flat washers.
Beforeinstalling,applyadropofthreadlockertothethreadsof
the SHCS.
❏ 2.ConnecttheESCtothemotor.TheESCcanbeattached
to the side of the motor box with hook and loop material.
❏ 3.Use hook and loop material to mount the receiver in the
fuselage. The antenna can be routed out the bottom of the
fuselage and taped to the covering.
INSTALLTHE RADIO SYSTEM
Install the Elevator Servo
❏ 1. Cut the covering away from the lower opening on the
left side, in the rear of the fuselage for the elevator servo.

13
❏ 2. Install a 16" [406mm] servo extension to the elevator
servo. Secure the extension to the lead with tape, a piece
of heat-shrink tubing some other method to keep them from
coming unplugged.
❏ 3. Install the elevator servo into the servo openings. Drill
through the servo mounting holes with a 1/16" [1.6mm] drill
bit. Remove the servo from the servo opening. Install and
then remove a servo mounting screw into each of the holes
you have drilled. Apply a drop of thin CA into the holes to
harden the threads. Once the glue has hardened install the
servo into the servo opening using the 2 x 7 x 9mm servo
retaining plates. Center the servo and then install a servo
arm with a hole 3/4" [19mm] from the center.
❏ 4.Thread a nylon clevis 16 turns onto a 2-56 x 6" [152mm]
wire pushrod.Connect the clevis to the second hole from the
base of a nylon control horn. Using the elevator pushrod,
position the control horn in line with the servo arm. When
positioned properly the control horn will rest on a hardwood
plate in the elevator.Mark the location of the mounting holes
onto the elevator. Drill a 1/16" [1.6mm] hole on the marks,
drilling through the elevator. Attach the control horn to the
elevator using two 2-56 x 3/4" [19mm] machine screws.
❏ 5. Slide a silicone clevis retainer over the clevis.With the
elevator servo and the elevator centered, mark the elevator
pushrod where it crosses the elevator servo arm. Make a
90° bend at the mark.Cut the pushrod 3/8" [9.5mm] past the
bend. Attach the pushrod to the elevator servo arm with a
nylon FasLink.
Install the Rudder Servo
Now is the time you need to decide on which rudder control
method you are going to use. Unless you are installing a
heavy motor, we recommend that you use the pull-pull system
to keep the weight out of the tail.To help you decide you can
install the wing, cowl and canopy. Mark the C.G. location on
the wing (shown on page 18).Then, place the plane on a C.G.
stand and position the flight battery in the middle of the battery
tray. If the plane is slightly tail heavy, we recommend that the
rudder pull-pull system be installed.If the plane is nose heavy,
the rudder servo can be installed in the tail.
Rudder Pull-Pull Installation
❏ 1. Install the rudder servo centered in the rudder pull-
pull servo tray. Drill through the servo mounting holes with
a 1/16" [1.6mm] drill bit. Remove the servo from the servo
opening. Install and then remove a servo mounting screw
into each of the holes you have drilled. Apply a drop of thin
CA into the holes to harden the threads. Once the glue has
hardened install the servo into the servo opening using the
2 x 7 x 9mm servo retaining plates. Center the servo, and
then install a servo arm as shown.

14
❏ 2. Cut the covering from over the two pull-pull exits at the
aft end of the two servo openings, between the openings.
❏ 3. Cut the pull-pull string in half. Put a small drop of thin
CA on one end of each piece of string. Allow the CA to cure
and trim off any frayed thread. Insert the end into the pull-pull
guide tubes in the fuselage.The string may be difficult to guide
through the exit. Once the string will not go any further into
the tube, use the point of a hobby knife to help pull the string
through the exit.Tape the string to the side of the fuselage at
the aft end to prevent it from being pulled through.
❏ 4.Measure up 3/4" [19mm] from the bottom of the rudder
and make a mark. Measure in from the leading edge 1/4"
[6.4mm] and make a mark.Drill a 3/32" [2.4mm] hole through
the rudder, perpendicular to the centerline of the rudder.
❏ 5.Insertthe2mmthreadedruddercontrolhornrod.Center
the rod in the rudder with two 2mm flat washers and 2mm
nuts on each side.A drop of threadlocker on the threads will
help prevent the nuts from coming loose.
❏ 6. Thread a nylon torque rod horn onto each end of the
control horn rod. Adjust the torque rod horn so that they are
both equal distance from the rudder.
❏ 7. Thread 2-56 nuts onto four 2-56 rigging couplers.
Slide a silicone clevis retainer over four threaded 2-56 metal
clevises.Then, thread the clevises 10 turns onto the rigging
couplers.Tighten the 2-56 nuts against the metal clevises.

15
❏ 8.Working from the end of the string inside the fuselage,
pass the string through a crimp, through the rigging coupler
and back through the crimp. Squeeze the crimp with a pliers
to secure the string in the crimp. Apply a drop of thin CA to
the crimp.
❏ 9.Attach the clevises to the rudder servo horn in the holes
3/4" [19mm] from the center.
❏ 10. Pull the pull-pull string out of the fuselage aft end
so that the string is tight. Pass the string through a crimp,
through the rigging coupler and back through the crimp.
Attach the clevis to the nylon torque rod horn on the rudder
and tape the string to the side of the fuselage.Repeat on the
other side of the fuselage.
❏ 11. With the rudder and the rudder servo arm centered,
pull the string tight at the rudder and squeeze the crimps to
secure the strings.
Rudder Servo Installation in theTail
❏ 1. Cut the covering away from the upper opening on the
right side, in the rear of the fuselage for the rudder servo.
❏ 2. Install a 16" [406mm] servo extension on the rudder
servo.Secure the extension to the lead with tape, a piece of
heat-shrink tubing or some other method to keep them from
coming unplugged.
❏ 3. Install the rudder servo into the servo opening. Drill
through the servo mounting holes with a 1/16" [1.6mm] drill
bit. Remove the servo from the servo opening. Install and
then remove a servo mounting screw into each of the holes
you have drilled. Apply a drop of thin CA into the holes to
harden the threads. Once the glue has hardened install the
servo into the servo opening using the 2 x 7 x 9mm servo
retaining plates. Center the servo, and then install a servo
arm as shown.
❏ 4. Thread a nylon clevis 16 turns onto a 2-56 x 6"
[150mm] wire pushrod. Connect the clevis to the second
hole from the base of a nylon control horn. Using the rudder
pushrod, position the control horn in line with the servo arm.

16
When positioned properly the control horn will rest on a
hardwood plate in the rudder.The center of the control horn
is approximately 5/8" [16mm] from the bottom of the rudder.
Mark the location of the mounting holes onto the rudder.Drill
a 1/16" [1.6mm] hole on the marks. Do not drill completely
through the rudder. Attach the control horn to the rudder
using two 2-56 x 3/4" [19mm] machine screws. Remove the
screws and apply a drop of thin CA to both holes. After the
CA has cured, reinstall the control horn.
❏ 5. Slide a silicone clevis retainer over the clevis. With
the rudder servo and the rudder centered, mark the rudder
pushrod where it crosses the rudder servo arm. Make a 90°
bend at the mark. Cut the pushrod 3/8" [9.5mm] past the
bend. Attach the pushrod to the rudder servo arm with a
nylon FasLink.
❏ 6. Connect the ESC, voltage regulator, rudder servo,
elevator servo and Y-harness to the receiver.
❏ 7. Connect the flight battery to the ESC and voltage
regulator. Check that all the servos are operating correctly.
Arm the motor (with the prop removed) and slowly start the
motor to make sure it is rotating in the correct direction.
❏ 8.Overlapby1" [25mm] twostripsofnonadhesive backed
hook and loop material. Route the hook and loop material
through the slot in the battery tray, under the tray and back
through the slot on the other side of the tray.
❏ 9. Attach a strip of sticky backed hook material to the
center of the battery tray.The loop material can be attached
to the battery.
Apply the Decals
The box photographs show the location of the decals on
the airplane. Refer to the box for the exact placement of the
decals.The following tips may be useful for applying them.
1.Be certain themodelisclean and free fromoilyfingerprints
and dust. Prepare a dishpan or small bucket with a mixture
of liquid dish soap and warm water–about one teaspoon of
soap per gallon of water.Submerse the decal in the soap and
water and peel off the paper backing.Note: Even though the
decals have a “sticky-back” and are not the water transfer
type, submersing them in soap and water allows accurate
positioning and reduces air bubbles underneath.
2.Position decals on the model.Holding the decal down, use
a paper towel to wipe most of the water away.
3.Use a piece of soft balsa or something similar to squeegee
remaining water from under the decal. Apply the rest of the
decals the same way.
GETTHE MODEL READYTO FLY
Check the Control Directions
❏ 1. Turn on the transmitter and receiver and center the
trims. If necessary, remove the servo arms from the servos
and reposition them so they are centered. Reinstall the
screws that hold on the servo arms.
❏ 2. With the transmitter and receiver still on, check all the
controlsurfacestoseeiftheyarecentered.Ifnecessary,adjust
the clevises on the pushrods to center the control surfaces.

17
❏ 3. Make certain that the control surfaces and the throttle
respond in the correct direction as shown in the diagram.
If any of the controls respond in the wrong direction, use
the servo reversing in the transmitter to reverse the servos
connected to those controls. Be certain the control surfaces
have remained centered. Adjust if necessary.
Set the ControlThrows
Use a ruler to accurately measure and set the control throw
of each control surface as indicated in the chart that follows.
If your radio does not have dual rates, we recommend setting
the throws at the low rate setting.
Note: The throws are measured at the widest part of the
elevators, rudder and ailerons.
These are the recommended control surface throws:
HIGH RATE
ELEVATOR: 3/4" [19mm], 12° up
3/4" [19mm], 12° down
RUDDER: 3-1/2" [89mm], 30° left
3-1/2" [89mm], 30° right
AILERONS: 3/4" [19mm], 15° up
3/4" [19mm], 15° down
LOW RATE
ELEVATOR: 1/2" [13mm], 8° up
1/2" [13mm], 8° down
RUDDER: 2" [51mm], 17° left
2" [51mm], 17° right
AILERONS: 1/2" [13mm], 10° up
1/2" [13mm], 10° down
3D RATE
ELEVATOR: 2-1/2" [64mm], 42° up
2-1/2" [64mm], 42° down
RUDDER: 5" [127mm], 45° left
5" [127mm], 45° right
AILERONS: 1-3/4" [44mm], 40° up
1-3/4" [44mm], 40° down
We also put exponential into the high rates and the 3D rates to
make the control throws less sensitive around neutral.These
can be set up to your own preference and flying style.We put
20% to 30% in the high rate and 50% to 60% in the 3D rates.
IMPORTANT: The Edge 540T EP has been extensively
flown and tested to arrive at the throws at which it flies
best. Flying your model at these throws will provide you
with the greatest chance for successful first flights.If, after
you have become accustomed to the way the Edge 540T
EP flies, you would like to change the throws to suit your
taste, that is fine. However, too much control throw could
make the model difficult to control, so remember, “more is
not always better.”

18
FINISHTHE MODEL
❏ 1. The cowl is held on with four magnets. It fits over the
small lip and snaps into place.Note: If you will be performing
violent maneuvers, a piece of clear tape should be applied to
both sides of the cowl to help hold it in place.
❏ 2. Use a prop reamer or drill bit to enlarge the spinner
backplate to fit your motor’s prop adapter. Install the spinner
backplate, propeller with washer and prop nut and the
spinner cone.Secure the spinner cone to the backplate with
two 3 x 10mm sheet metal screws.
❏ 3. Insert a flight battery in the fuselage and use the hook
and loop material to hold the battery in position. Do not
connect the battery to the ESC while balancing the model.
❏ 4. Install the canopy.
Balance the Model (C.G.)
More than any other factor, the C.G. (balance point) can
have the greatest effect on how a model flies, and may
determine whether or not your first flight will be successful.
If you value this model and wish to enjoy it for many flights,
DO NOT OVERLOOK THIS IMPORTANT PROCEDURE.
A model that is not properly balanced will be unstable and
possibly unflyable.
At this stage the model should be in ready-to-fly condition
with all of the systems in place including the motor, landing
gear, covering and paint, and the radio system.
❏ 1.Use a felt-tip pen or 1/8" [3mm]-wide tape to accurately
mark the C.G. on the top of the wing at the side of the
fuselage.The C.G. is located 2-13/16" [71mm] back from the
leading edge of the wing at the side of the fuselage.
This is where your model should balance for the first
flights. Later, you may wish to experiment by shifting the
C.G. up to 3/16" [5mm] forward or 3/16" [5mm] back to
change the flying characteristics. Moving the C.G. forward
may improve the smoothness and stability, but the model
may then require more speed for takeoff and make it more
difficult to slow for landing. Moving the C.G. aft makes
the model more maneuverable, but could also cause it to
become too difficult to control. In any case, start at the
recommended balance point and do not at any time
balance the model outside the specified range.
❏ 2.With the wing attached to the fuselage, all parts of the
model installed (ready to fly), lift the model at the balance
point you marked.
❏ 3.If the tail drops, the model is“tail heavy”and the battery
pack and/or receiver must be shifted forward or weight
must be added to the nose to balance. If the nose drops,
the model is “nose heavy” and the battery pack must be
shifted aft or weight must be added to the tail to balance. If
additional weight is required, use Great Planes (GPMQ4485)
“stick-on” lead. A good place to add stick-on nose weight is
to the motor box (don’t attach weight to the cowl–it is not
intended to support weight). Begin by placing incrementally
increasing amounts of weight on the fuselage over the motor
box until the model balances.Once you have determined the
amount of weight required, it can be permanently attached.
Note: Do not rely upon the adhesive on the back of the
lead weight to permanently hold it in place. Over time the
adhesive may soften and cause the weight to fall off.Use #2
sheet metal screws, RTV silicone or epoxy to permanently
hold the weight in place.
❏ 4.IMPORTANT:Ifyoufounditnecessarytoaddanyweight,
recheck the C.G. after the weight has been installed.

19
Balance the Model Laterally
❏ 1. With the wing level, have an assistant help you lift the
model by the motor propeller shaft and the bottom of the
fuselage under the TE of the fin.Do this several times.
❏ 2. If one wing always drops when you lift the model, it
means that side is heavy. Balance the airplane by adding
weighttotheotherwingtip.Anairplanethathasbeenlaterally
balanced will track better in loops and other maneuvers.
PREFLIGHT
IdentifyYour Model
No matter if you fly at an AMA sanctioned R/C club site or if
you fly somewhere on your own, you should always have your
name, address, telephone number and AMA number on or
inside your model.It is required at all AMA R/C club flying sites
and AMA sanctioned flying events. Fill out the identification
tag on page 22 and place it on or inside your model.
Charge the Batteries
Followthebattery charginginstructions thatcamewithyourradio
control system to charge the batteries.You should always charge
your transmitter batteries the night before you go flying, and at
other times as recommended by the radio manufacturer.
CAUTION: Unless the instructions that came with your
radio system state differently, the initial charge on new
transmitter and receiver batteries should be done for 15
hours using the slow-charger that came with the radio
system.This will “condition” the batteries so that the next
charge may be done using the fast-charger of your choice.
If the initial charge is done with a fast-charger the batteries
may not reach their full capacity and you may be flying with
batteries that are only partially charged.
Balance Propellers
Carefully balance your propeller and spare propellers before
youfly.Anunbalancedpropcanbethesinglemostsignificant
cause of vibration that can damage your model. Not only
will motor mounting screws and bolts loosen, possibly with
disastrous effect, but vibration may also damage your radio
receiver and battery.
We use a Top Flite Precision Magnetic Prop Balancer
(TOPQ5700) in the workshop and keep a Great Planes
Fingertip Prop Balancer (GPMQ5000) in our flight box.
Range Check
Ground check the operational range of your radio before the
first flight of the day. With the transmitter antenna collapsed
and the receiver and transmitter on, you should be able
to walk at least 100 feet [30m] away from the model and
still have control. Have an assistant stand by your model
and, while you work the controls, tell you what the control
surfaces are doing.Repeat this test with the motor running
at various speeds with an assistant holding the model, using
hand signals to show you what is happening. If the control
surfacesdonotrespondcorrectly,donotfly!Findandcorrect
the problem first.Look for loose servo connections or broken
wires, corroded wires on old servo connectors, poor solder
joints in your battery pack or a defective cell, or a damaged
receiver crystal from a previous crash. The problem may be
the location of the antenna. The antenna should be as far
away from the ESC and battery as possible.
MOTOR SAFETY PRECAUTIONS
Failure to follow these safety precautions may result
in severe injury to yourself and others.
Get help from an experienced pilot when learning to operate
electric motors.
Use safety glasses when running electric motors.

20
Do not run the motor in an area of loose gravel or sand; the
propeller may throw such material in your face or eyes.
Keep your face and body as well as all spectators away from
the plane of rotation of the propeller as you run the motor.
Keep these items away from the prop: loose clothing, shirt
sleeves, ties, scarfs, long hair or loose objects such as
pencils or screwdrivers that may fall out of shirt or jacket
pockets into the prop.
The motor gets hot! Do not touch it during or right after
operation.
When working on your plane, remove the propeller if the
motor battery will be connected.
Always remove the motor battery from the plane when
charging.
Follow the charging instructions included with your charger
for charging LiPo batteries.LiPo batteries can cause serious
damage if misused.
AMA SAFETY CODE (excerpts)
Read and abide by the following excerpts from the Academy
of Model Aeronautics Safety Code. For the complete Safety
Code refer to Model Aviation magazine, the AMA web site or
the Code that came with your AMA license.
General
1) Iwillnot flymy modelaircraftinsanctioned events, air shows,
or model flying demonstrations until it has been proven to be
airworthy by having been previously, successfully flight tested.
2) I will not fly my model aircraft higher than approximately
400 feet within 3 miles of an airport without notifying the
airport operator.I will give right-of-way and avoid flying in the
proximity of full-scale aircraft.Where necessary, an observer
shall be utilized to supervise flying to avoid having models fly
in the proximity of full-scale aircraft.
3) Where established, I will abide by the safety rules for the
flying site I use, and I will not willfully and deliberately fly my
models in a careless, reckless and/or dangerous manner.
5) I will not fly my model unless it is identified with my name
and address or AMA number, on or in the model. Note: This
does not apply to models while being flown indoors.
7) I will not operate models with pyrotechnics (any device
that explodes, burns, or propels a projectile of any kind).
Radio Control
1)I willhave completed asuccessful radioequipmentground
check before the first flight of a new or repaired model.
2) I will not fly my model aircraft in the presence of spectators
until I become a qualified flier, unless assisted by an
experienced helper.
3) At all flying sites a straight or curved line(s) must be
established in front of which all flying takes place with the
other side for spectators.Only personnel involved with flying
the aircraft are allowed at or in the front of the flight line.
Intentional flying behind the flight line is prohibited.
4) I will operate my model using only radio control frequencies
currently allowed by the Federal Communications Commission.
5) I will not knowingly operate my model within three
milesofanypre-existingflyingsiteexceptin accordance
with the frequency sharing agreement listed (in the
complete AMA Safety Code).
9) Under no circumstances may a pilot or other person
touch a powered model in flight; nor should any part of the
model other than the landing gear, intentionally touch
the ground, except while landing.
CHECK LIST
During the last few moments of preparation your mind may
be elsewhere anticipating the excitement of the first flight.
Because of this, you may be more likely to overlook certain
checksand proceduresthat shouldbe performed before the
model is flown.To help avoid this, a check list is provided to
make sure these important areas are not overlooked.Many
arecovered in the instructionmanual,so where appropriate,
refer to the manual for complete instructions. Be sure to
check the items off as they are completed.
❏1. Check the C.G. according to the measurements
provided in the manual.
❏2. Be certain the battery and receiver are securely
mounted in the fuselage. Simply stuffing them into
place with foam rubber is not sufficient.
❏3. Extend your receiver antenna and make sure it has a
strain relief inside the fuselage to keep tension off the
solder joint inside the receiver.
❏4. Balance your model laterally as explained in
the instructions.
❏5. Use threadlocking compound to secure critical
fasteners such as the motor screws, wheel collar
SHCS and screw-lock pushrod connectors, etc.
❏6. Add a drop of oil to the axles so the wheels will
turn freely.
❏7. Make sure all hinges are securely glued in place.