Hangar 9 EDGE 540 User manual

PRE-BUILT
90
%
54
0540
EDGE
EDGE
Ultra Aerobatic 1.20 ARF
EDGE
EDGE
EDGE
EDGE
TM
TM
Specifications
Wingspan: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78′′ 198.10 cm
Length: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.5′′ 174 cm
Wing Area:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010 sq. in 651.6 dm2
Weight (Approx.): . . . . . . . . . . . . . . . . . . . . 11-13 lbs 5-5.9 kg
Recommended Engines: 1.08 –1.50 2-Stroke
1.20 –1.80 4-Stroke
• 90% prebuilt
• High-quality hardware included
• Precovered in genuine Goldberg UltraCote®
• Prefinished fiberglass cowl and wheel pants
INSTRUCTION MANUAL

2
TABLE OF CONTENTS
Introduction 3
Warning 3
Additional Required Equipment 3
Tools and Supplies Required (not included in kit) 4
Contents of Kit 5
Section 1. Hinging the Ailerons 6
Section 2. Joining the Wing Halves 9
Section 3. Installing the Aileron Servos 12
Section 4. Installing the Aileron Linkages 14
Section 5. Mounting the Wing to the Fuselage 16
Section 6. Installing the Tail (Vertical and Horizontal Stabilizers) 17
Section 7. Hinging the Horizontal Stabilizer and Elevator(s) 20
Section 8. Hinging the Rudder and Installing the Tailwheel 21
Section 9. Installing the Rudder and Elevator Control Horns 23
Section 10. Mounting the Main Landing Gear 26
Section 11. Assembling and Mounting the Wheel Pants 27
Section 12. Installing the Engine (2/4 Stroke) 29
Section 13. Assembling and Installing the Fuel Tank 30
Section 14. Installing the Radio 32
Section 15. Installing the Control Linkages (Rudder/Elevator/Throttle) 34
Section 16. Attaching the Cowling 37
Section 17. Mounting the Hatch (with Canopy) 39
Section 18. Adding Decals 41
Section 19. Balancing the Edge 540 42
Section 20. Control Throw Recommendation 42
Set-up & Flying by Mike McConville 43
Preflight at the Field 49
AMA Safety Code 50

Saito 1.80
MDS 1.48
Introduction
Thank you for purchasing the Hangar 9 Edge 540. This is the latest aerobatic line of fine ARFs (Almost-Ready-to-Fly) produced by
Hangar 9. The Edge 540 is a high-performance aircraft best suited for the more experienced flyer and modeler. Although this is an
ARF, it does have some construction features that can be challenging for a new modeler. If you encounter difficulty in any construction
sequence, please contact one of our technicians. We provide any assistance we can concerning the construction of your Edge 540.
Please feel free to contact us at:
Horizon Hobby, Inc.
4105 Fieldstone Road
Champaign, IL 61822
[phone]
www.horizonhobby.com
Warning
An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in open areas, preferably
AMA (Academy of Model Aeronautics) approved flying sites, following all instructions included with your radio and engine.
Additional Required Equipment
Radio Equipment
4 channels minimum
5 servos (50 in/oz plus servo for standard flying
and 90 in/oz plus servos for 3-D flying)
1100mAh Receiver Battery (JRPB4240)
Y-Harness (if not using a computer radio) (JRP133)
12” Aileron Extensions (2) (JRPA098)
Engine Requirements:
1.08 – 1.48 2-cycle engines
1.20 – 1.80 4-cycle engines
Recommended 2-Cycle Engines Recommended 4-Cycle Engines
Webra 1.20 Saito 1.20 – 1.80
Moki 1.35 Saito 1.20 GK – 1.80 GK
MDS 1.48
Additional Items Optional Items
12” Aileron Extension (2) (JRPA098)
3” Tru-Turn Spinner (TRU 3002)
True Turn Adapter for specific engine
Propeller:
MDS 1.48 = 16” x 8” (recommended)
Saito 1.80 = 16” x 8” (recommended)
Fuel tubing
3
Recommended JR Radio Systems:
JR400EX JR XP783
JR 421EX JR XP8103
JR XP652 JR PCM10X
Fuel Dot (HAN115)
Pitts style muffler for
specific engine (if using MDS 1.48)
Fuel Filter (HAN143)
Foam for cushioning radio and fuel tank
(DUB513)
Antenna Tube (HAN112)
Pilot figure (HAN8272 or HAN8275)
Instrument Panel (HAN186)

4
Tools and Supplies Required
Adhesives
Thin CA (Cyanoacrylate) glue
Thick CA (Cyanoacrylate) glue
6-Minute Epoxy (HAN8000)
30-Minute Epoxy (HAN8002)
Tools
Drill
Drill bits: 1/16'', 1/18'', 5/32'', 1/14''
Soldering iron
Phillips screwdriver
Z-bend pliers
CA remover/debonder
Standard pliers
Mixing sticks
5/32” hex wrench
Medium sandpaper
Moto-tool with sanding drum and cut-off wheel
Hobby knife with #11 blade
Masking tape
Threadlock Z-42 (Pacer)
Canopy Glue (Pacer PAAPT56)
Silver Solder (Staybrite)
Epoxy brushes
Scissors
Straight edge
Rubbing alcohol
1/16” hex wrench
Sanding stick (medium)
Small round file
Paper towels
Felt-tipped pen or pencil
90-degree triangle
Measuring device (36”)

5
Contents of Kit
Large Parts
Fuselage (HAN1351)
Left Wing Half with Aileron (HAN1352)
Right Wing Half with Aileron (HAN1352)
Vertical Stabilizer with Rudder (HAN1353)
Horizontal Stabilizer with Elevator(s) ( HAN1353)
Cowl (HAN1354)
Wheel Pants (HAN1355)
Hatch (HAN1358)
Other Parts
Main landing gear (HAN1356)
Wheels (2) (HAN2027)
Fuel tank and hardware (HAN1460)
Trim sheets (HAN1359)
Metal motor mount and hardware (HAN2033)
Tail wheel assembly (HAN2026)
Canopy (HAN1357)
Note: Instrument Panel (HAN186) is optional.
1/4 scale pilot optional (HAN8272 or HAN8275)

6
Note: The control surfaces, including the ailerons, elevators,
and rudder, are prehinged with hinges installed, but
the hinges are not glued in place. It is imperative that
you properly adhere the hinges in place per the steps
that follow using a high-quality thin CA glue.
Step 1. Carefully remove the aileron from one of the wing
panels. Note the position of the hinges. The Edge 540 comes
with high-quality CA-type hinges.
Step 2. Remove each hinge from the wing panel and aileron
and place a T-pin in the center of each hinge. Slide each hinge
into the aileron until the T-pin is snug against the aileron. This
will help ensure an equal amount of hinge is on either side of
the hinge line when the aileron is mounted to the wing panel.
Step 3. Slide the aileron on the wing panel until there is only a
slight gap. The hinge is now centered on the wing panel and
aileron. Remove the T-pins and snug the aileron against the wing
panel. A gap of 1/64” or less should be maintained between the
wing panel and aileron.
Step 4. Deflect the aileron and completely saturate each hinge
with thin CA glue. The aileron’s front surface should lightly
contact the wing during this procedure. Ideally, when the hinges
are glued in place, a 1/64” gap or less will be maintained
throughout the length of the aileron to the wing panel hinge line.
Note: The hinge is constructed of a special material that
allows the CA to wick or penetrate and distribute
throughout the hinge, securely bonding it to the
wood structure of the wing panel and aileron.
Step 5. Turn the wing panel over and deflect the aileron in the
opposite direction from the opposite side. Apply thin CA glue to
each hinge, making sure that the CA penetrates into both the
aileron and wing panel.
Section 1: Hinging the Ailerons
• Right wing panel with aileron and hinges
• Left wing panel with aileron and hinges
• Instant thin CA glue
• CA remover/debonder
• Paper towels
• T-pin (one for each hinge)(optional procedure)
Parts Needed Tools and Adhesives Needed

7
Step 6. Using CA remover/debonder and a paper towel,
remove any excess CA glue that may have accumulated on the
wing or in the aileron hinge area.
Step 7. Repeat this process with the other wing panel, securely
hinging the aileron in place.
Step 8. After both ailerons are securely hinged, firmly grasp
the wing panel and aileron to make sure the hinges are securely
glued and cannot be pulled out. Do this by carefully applying
medium pressure, trying to separate the aileron from the wing
panel. Use caution not to crush the wing structure.
Note: Work the aileron up and down several times to “work
in” the hinges and check for proper movement.
Sealing the Hinge Gaps
It’s imperative that the aileron and elevator hinge lines be sealed
airtight to prevent flutter. Sealing the hinge line has several
advantages. A sealed hinge line gives a greater control response
for a given control deflection. It also offers more precise,
consistent control response and makes trimming easier.
Sealing the aileron and elevator hinge line is
mandatory. Failure to do so may cause control surface
flutter, resulting in a crash.
Step 9. Cut a piece of clear or blue UltraCote®(not included)
for sealing the ailerons to approximately 3'' x 28''. Fold the
UltraCote®down the center with the adhesive side to the outside
making a sharp crease at the fold.
Step 10. Using a ruler, measure 3/8'' from the folded crease
and mark two places with a pen.
Section 1: Hinging the Ailerons
CONTINUED

8
Sealing the Hinge Gaps (continued)
Step 11. Using a sharp #11 blade and a straight edge, carefully
cut through both layers of UltraCote®covering at the 3/8'' point
marked in Step 2.
Step 12. Mark and cut the folded covering to an overall length
of 25 5/6''. This piece will be inserted and ironed down into the
hinge bevel on the bottom of the aileron.
Step 13. Remove the backing from the UltraCote®. Place the
folded crease side into the center of the hinge line on the bottom
of the wing. Using a straight edge as shown, hold one side of the
overing in place while ironing down theopposite side with a
sealing iron. We recommend setting the iron temperature to
320° for this operation.
Step 14. Fully deflect the aileron in the up position. Place the
straight edge over the hinge line covering that you just ironed
down in Step 5 with the edge of the straight edge placed firmly at
the bottom of the hinge line as shown. Iron down this side of the
covering, making sure the aileron is fully deflected.
Section 1: Hinging the Ailerons
CONTINUED

9
Step 1. Locate the plywood wing joiner. Using the ruler,
determine the center of the wing joiner and mark it with a felt-
tipped pen or pencil.
Step 2. Trial fit the wing joiner into one of the wing panels. It
should insert smoothly up to the center line marked in Step 1.
Now slide the other wing panel onto the wing joiner until the
wing panels meet. If the fit is overly tight, it may be necessary to
sand the wing joiner.
Step 3. The correct dihedral angle for the wing is 0 degrees (at
the center line). Place the wing on a large flat surface one wing
panel resting on the flat surface. The other wing tip should be at
11/8'' in height from the surface (see illustration below). If
necessary, sand the wing joiner until this is achieved. There
should be no gaps in the wing center. Once you are satisfied
with the fit, remove the wing joiner from the wing panels.
Step 4. Mix approximately 1 ounce of 30-minute epoxy.
Note: It is extremely important to use plenty of epoxy when
joining the wing panels together. It will also be helpful
to use wax paper under the wing center when epoxying
the wing panels together.
Step 5. Using an epoxy brush or a scrap piece of wood, apply a
generous amount of epoxy into the wing dihedral cavity in one
wing panel.
Step 6. Coat one half of the wing joiner with epoxy up to the
line marked in Step 1. Install the epoxy-coated side of the
dihedral brace into the wing panel cavity up to the marked
center line.
• Right/left wing panels
• Dihedral brace
• Plywood wing dowel plate
• Wooden dowels
• Wing bolt plates
• Wing trim tape
• 30-minute epoxy
• 6-minute epoxy
• Mixing stick
• Epoxy brush
• Masking tape
• Hobby knife w/#11 blade
Parts Needed Tools and Adhesives Needed
Section 2: Joining the Wing Halves
• Rubbing alcohol
• Paper towels
• Wax paper
• Ruler
• Felt-tipped pen or pencil
• Medium sandpaper
Flat Surface
11/8''
0°

10
Step 7. Apply a generous amount of epoxy into the other wing
panel cavity.
Note: You may need to mix up more epoxy to complete the
joining process.
Step 8. Now apply epoxy to all sides of the exposed wing
joiner and uniformly coat both wing roots with epoxy.
Step 9. Carefully slide the two wing halves together and firmly
press them together, allowing the excess epoxy to run out. There
should not be any gap in the wing halves. Use rubbing alcohol
and a paper towel to clean up any excess epoxy.
Step 10. Apply masking tape at the wing joint to hold the wing
halves together securely. Place the wing on a flat surface. With
the center wing panels firmly supported to lay flat on the surface,
the wing tips should be propped up so it is 11/8'' from the surface.
Apply more masking tape the center wing joint and recheck the
11/8'' measurement. Allow the wing joint to dry overnight.
Note: It is useful to use wax paper underneath the wing
center while the epoxy is curing. This will help prevent
excess epoxy from adhering to the work surface.
Section 2: Joining the Wing Halves
CONTINUED