PAU Edge540 User manual

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150 to 200cc Edge540 and 540T ARF
Instruction Manual
Congratulations and thank you for purchasing the Performance Aircraft Unlimited 43% Edge 540. The Zivko
Edge 540 was designed and developed to be the best aerobatic aircraft in the world and it delivered! Not only
does this aircraft dominate IAC competition but has also found a home in the Red Bull racing circuit where it
has won title after title. The 540 stands for the powerful Lycoming 540 motor that puts out more than 300hp.
Made from modern composites, this aircraft is sure to be on the podium for some time to come.
The PAU Edge is no different! Designed with 2963 sq inches of wing area while keeping the total weight down
has made this aircraft a true performer. All wood construction and top quality hardware make it hard to beat. If
you want an aircraft precise enough to compete in IMAC or to turn it loose for the wildest 3D maneuvers on the
planet, the 36% PAU Edge’s are the only choice. PAU has also increased the aileron size and really beefed up
the wings. The fuse is redesigned and now accepts the DA-120 and has a much more aggressive stance. More
side area and stubble surface changes clean this aircraft up further in knife. Just as it’s full-scale counterpart,
the PAU Edge has found victory in competition aerobatics.

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We believe you will find this to be one of the finest flying aircraft on the market. Most modelers will find
assembly of this aircraft simple and straightforward. We recommend the builder follow the step-by-step
instructions to achieve the best performance and to ensure nothing was over looked. This manual also includes
tip sections throughout that may help you in key areas during assembly. Please familiarize yourself with this
manual before assembly.
This manual is broken down into ten chapters for simplicity:
Chapter 1 - Parts Inventory
Chapter 2 - Preparation for Assembly
Chapter 3 - Landing Gear and Tail Wheel Assemblies
Chapter 4 - Canopy and Fuselage Hatch
Chapter 5 - Engine Installation
Chapter 6 - Cowling installation
Chapter 7 - Rudder Installation
Chapter 8 - Hardware Installation
Chapter 9 - Radio and Control Surface Setup
Chapter 10 - Final Inspection and Pre-Flight
Additional items needed to complete this aircraft, which are not included:
 An engine, within the recommend range, and propeller
 8 channel computer radio and receiver recommended
 Batteries and switches (with regulators if using Ion batteries)
 Six aileron servos rated at least at 150oz of torque
 Four elevator servos rated at least at 200oz of torque each!
 Two or three rudder servos rated at least at 800oz of torque combined
 One throttle servo with push rod and links
 Optional choke servo with push rod and links
 One fueling dot or fueling device
 3 to 4 feet of fuel tubing
 Foam rubber
 5” inch spinner
 30 to 45 minute epoxy
 A bottle of thin CA
 Covering iron
 Various modeling tools for assembly
 ½ inch low tack masking tape
Using fewer servos then specified will not be covered under warranty! This is a large aircraft with very
large control surfaces that require better than average servos.
As with any aircraft this size, more care needs to be taken when flying. Aircraft this size susceptible to
damage or failure due to high G loading due to excessive speed during hard maneuvers. Watch your
speed! Since it’s an Edge, it wants to rotate more easily from normal flight to fully stalled conditions which
if not careful can over stress the airframe. This is one of the reasons Edge are so popular for 3D

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Chapter 1
Parts inventory
Place an “×
××
×” to ensure your kit is
complete:
 1 Fuselage
 1 Fuselage access hatch
 2 Wing panels (1 right and 1 left)
 2 Horizontal stabilizers (1 right and 1
left)
 1 Rudder
 1 Fiberglass Cowl
 1 Pair of fiberglass wheel pants
 1 CF landing gear
 1 Pair of Dubro Light wheels
 1 CF Tail wheel and tiller assembly
 1 Canopy
 1 Carbon fiber wing
 1 Carbon fiber stabilizer tube
 4 Nylon wing retention bolts
 10 H9 titanium pushrods/turnbuckles
 1 set of Dubro wheel collars
 1 pair of Dubro wheel axels
 1 HD Dubro pull-pull system
 1 Set of aluminum control horn
assemblies
 1 50oz Dubro fuel tank
 12 HD 4/40 Dubro ball links
 1 Set of additional various marked
hardware
 1 Vinyl graphics package
If any of these parts are missing immediately contact PAU.
If you need more information you can visit our support forum at: flyinggiants.com

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Chapter 2
Preparation for Assembly
Professionals utilizing premium Ultracote covering carefully covered your model. Due to climate changes
during shipping, the models covering may have loosened and/or winkled. It’s a good habit to go over your
model with a covering iron to ensure all joints, seams, and edges are properly sealed.
Ultracote is a lower temperature film that seals and shrinks at lower temperatures. Make sure you set your iron
on a low temperature initially to get a feel for the correct temperature setting and adjust accordingly. Higher
temperatures will cause your covering to over shrink and distort. Also, use a sock over your iron to ensure a
scratch free finish.
Place an “×
××
×” to ensure task completion:
 Go over you model as necessary with a
covering iron to insure all joints, seams,
and corners are sealed properly.
 Use your iron to ensure the areas where
cutouts are needed for your hardware are
located and sealed down, such as servos;
tubes, and control horn mounting
locations.
Next, we’ll need to cut out the covering at the
locations for hardware and final assembly. Make sure you use a sharp hobby knife so your cuts will be clean
and straight.
 Start with the fuselage, Locate and cut
out the servo and stabilizer and wing
tube locations.
 Locate and cut the location for the anti-
rotation pins and mounting holes for the
stabilizers and wings.
 Locate and cut the two mounting bolt
locations for the canopy and the two
pull-pull exits.
 Locate and cut the servo mounting
locations for each wing half.

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Optional step
Side windows and rear inspection glass.
Included with you kit are optional lower pilot side windows and the rear inspection windows. This adds
a nice touch to your aircraft and gives a little more scale uniqueness.
 Locate the windows in your kit.
 Using a sharp exacto knife, locate the window frames
in the fuse and carefully cut through the covering and
into the laser cut lines in the fuse.
 Remove the covering and carefully remove the wood
within the frame.
 Test fit the windows, as
some slight trim work may be
required. Once your happy with
the fit, remove the protective
plastic backing from the window
and glue in place. We
recommend glue like RC-56 as
it’s very strong and will dry clear. CA will fog and is not
recommended.
 Once windows are installed, you may wish to use ¼” trim and frame
the window. This will give you a very clean install and look.

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Chapter 3
Landing Gear and Tail Wheel Assemblies
Now that we’re ready for assembly, we are going to start with the main landing gear first. You will need to
locate the following parts to begin assembly.
Place an “×
××
×” to ensure task completion:
 What you will need in this chapter for the main gear:
 Aluminum main gear
 One pair of 4.5” inch wheels
 One pair of wheel pants
 One pair of Dubro axles
 Four wheel collars
 Hardware pack marked “wheels”
 Fuselage
 Rudder
 Carbon Fiber Tail wheel assembly
Not Provided:
 ½” and a 9/16” inch wrench
 Blue loc-tite
 Allen wrench for wheel collars
 White wood glue such as Elmer’s or
Epoxy
 Fasten the axles to the main landing gear
with the lock nuts.
 Using your four wheel collars and wheels,
center you wheels on the axles. Place the
collars as close to the wheels as possible but
ensure the wheels still rotate freely. Again,
we don’t want the wheel to move from side
to side and contact the wheel pants. Also,
we recommend the use of loc-tite on the
setscrews of the wheel collars to prevent
them from vibrating loose.

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 First you’ll need to nock out the plywood opening the canister tunnel. Use a hobby knife on the small
area not cut with a laser and lightly tap it out with a small hammer.
 Install the landing gear to the fuselage using the four 8/32 bolts, spring washers, and flat washers, and
compression nuts.
Now lets get the tail wheel assembly installed.
 Once the mains are on, find the holes for the tail wheel assembly and open.
 Once the mains are on, find the pre-marked holes for the tail wheel assembly and drill out for 6/32
bolts. Install assembly using loc-tite.
 Install the steel tiller horn just behind the hinge line on the bottom of the rudder using the two small
wood screws.
Tip#2 Set aside your two tiller springs, we will install those later after the rudder is mounted.

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 Cut out the center wheel opening on the wheel pants on the side with the wood-mounting block.
 With the aircraft resting on the landing gear, we are going to need to set the right angle for the wheel
pants. We used a standard servo and placed it at the end of the pant resting the end on the rubber
grommets of the servo. Mark the drilling location for the 4/40 bolts.
 Drill the holes for the 4/40 bolts in the wheel pants at the locations you’ve marked.
 Apply some white wood or epoxy glue to the inner side of the four 4/40 blind nuts and install the blind
nuts to the inside of the wheel pants.
 Now you can install the wheel pants with the 4/40 bolts and washers. Don’t forget to use loc-tite here
again. Wheel pants tend to take the most vibration.

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Chapter 4
Canopy and Fuselage Hatch
Place an “×
××
×” to ensure task completion:
 Gather the following for canopy and hatch
installation:
 Canopy
 Fuselage and Access Hatch
 8 to 16 small wood screws
 4 6/32 bolts with two sealing
washers
Not Provided:
 Drill and small drill bit for wood
screws
 Canopy glue (optional)
 Thin CA
 Ruler
 Install the hatch on the fuselage using two 6/32 bolts with the self-sealing washers.
 Trial fit the canopy to the fuselage access hatch to determine screw locations.
 Mark four to eight evenly spaced locations for the screws on each side. Double check to ensure all the
marked screw locations will go into the hatch rail.
 Remove canopy from the access hatch and drill the marked locations for the canopy screws.
 Install the canopy using the small wood screws. If satisfied with
the fit, remove the canopy and hatch and wick a small amount of
thin CA into each of the screws holes on the hatch. Once dried,
reinstall canopy with optional canopy glue if desired. Caution!
CA will fog the canopy if installed before completely drying.

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Chapter 5
Engine Installation
Your kit comes with both a firewall pre-mounted and an extra firewall for DA-200 installation. You can choose
from a wide variety of engine choices. It is nearly impossible to cover every engine installation choice in this
manual but we’ll cover a few. Your aircraft was designed around the 150cc to 170cc twin gas motors as well as
the 200cc quads. Also, we have provided a canister/pipe tunnel on our Edge for those desire quieter operation.
Please consult the manufacturer for the installation of optional canisters/pipes.
The best way to get perfect alignment with the motor and cowl is to stand the fuse on it’s tail and rest the motor
in place on the firewall. Rest cowl in place, adjust motor, and remove cowl mark and drill. While you can use
the pre-marked firewall, this may by slightly off due to variances when cutting the cowl from the molds.
DA-150/170 installation
 The firewall is pre-marked so you'll just need to center your motor in the "+". Take a ruler and draw a
line across the entire firewall for the thrust line and offset centerline.
 DA-150/170 users only. Center the motor based on your dimensions and drill out the holes for the ¼-20
bolts.
 Mount the motor using 3/4" standoffs for the DA-150/170, and four 1/4-20 x 2" long bolts.
 Now that you have the motor mounted, mark the locations for the fuel line and throttle push rod remove
motor and drill those locations and reinstall motor.
We recommend 4/40 push rods for throttle and/or optional choke servo. Also ensure there is no metal-to-
metal contact from the throttle/choke to the servos. 2/56 Ball links for 4/40 rod (not included) will prevent
the aforementioned metal-to-metal contact and will bolt to nicely to your motors carburetor.

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Chapter 6
Split Cowling installation
Place an “×
××
×” to ensure task completion:
 What you will need in this chapter:
 Fuselage and cowling
 Six 6/32 bolts with spring and lock
washers
 12 button head 6/32 bolts and nylon
washers (split cowl)
Not Provided:
 A 5” inch spinner
 A Dremel tool
 A facemask and eye protection
 Pencil or dry erase marker
We have provided a split cowl with your Edge. This allows better baffling setups as well as making it easier
when installing a DA-200. Always wear a mask and eye protection while cutting fiberglass. Take your time
while installing the cowl. With care you will end up with a professional installation that will make an
impression at the field.
Close the choke and place a piece of tape over the carburetor inlet and exhaust outlet to keep out any dust while
setting up your cowl. Since the cowl is preset and uses a ring to mount, there will not be much to do here.
 First cut out the bottom opening for cooling. For the DA-
150/170/200 using canisters, you will only need to open
the bottom of the cowl to exit the air from the cowl. If
your using stock exhaust stacks, it maybe necessary to cut
away the bottom portion of the cowl-ring for it to pass the
exhaust.
 If using stock mufflers for the DA-150/170, we recommend
the compact style.
 Remove the
cowling and
cut out the
remaining
areas to be
trimmed.
Simple canister setup
depicted right.

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Chapter 7
Control Surface Installation
Place an “×
××
×” to ensure task completion:
 What you will need in this chapter:
 Entire airframe
 Provided hinges
Not Provided:
 30 to 45 minute epoxy
 Two cycle oil
 9. Now were going to prep the hinges for installation. Take a small drop of oil and place it in each of
the pivot points of your hinges. The oil prevents excess epoxy from bonding the joint (figure 72).
 10. Working with one panel and control surface at a time, apply epoxy into the hinge holes of the
trailing edge. Apply epoxy to one side of the hinges and insert them into the holes (figure 73, 74, and
75).
 11. Apply epoxy into the leading edge holes of the control surface and the other side of the hinges.
 12. Carefully insert the control surface into the hinges and butt the two surfaces together. Move the
surface up and down a couple of times to make sure all the hinges are aligned correctly and the desired
throw is attained. 35 degrees for ailerons and 45 degrees for all others (figure 76).
 13. Use some masking tape to hold the surfaces together and let cure for at least eight hours. Repeat
these steps until all of the surfaces are epoxied in place (figure 77).

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 14. Install the tiller springs you set aside in chapter 2 to the tiller horn and tiller.
Tip#4 Optional step. After your epoxy has cured, it would be a good time to seal all of your hinge gaps prior to
installing you hardware. This can provide you with a better flying aircraft by increasing control surface
performance and preventing possible flutter. Clear or matching covering material can be ironed in place to fill
any gaps on the bottom of your control surfaces.
Take approximately a one-inch strip of covering the length of your surface. Fold it in half while placing into
the gap with the control surface fully deflected up and iron it in place. Check to make sure you still have full
surface travel once you have completed (figure 78,79, and 80).
Tip#5 Optional step. After your epoxy has cured, it would be a good time to seal all of your hinge gaps prior
to installing the rest of the hardware. This can provide you with a better flying aircraft by increasing control
surface performance and preventing possible flutter. Clear or matching covering material can be ironed in
place to fill any gaps on the bottom of your control surfaces.
Take approximately a one-inch strip of covering the length of your surface. Fold it in half while placing into
the gap with the control surface fully deflected up and iron it in place. Check to make sure you still have full
surface travel once you have completed.

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Chapter 8
Hardware Installation
We provide high quality aluminum control horn assemblies included with our latest generation of PAU aircraft
kits. We believe these lightweight assemblies are the best available and can also be purchased separately from
PAU.
Place an “×
××
×” to ensure task completion:
 What you will need in this chapter:
 The entire airframe
 Ten H9 titanium push rods
 Ten sets of aluminum control horn assemblies
 Ten steel posts, 80mm. You will have extras
that are too short. Use the long ones for
ailerons.
 12 HD Dubro ball links
 One 50oz Du-bro fuel tank
 Pull-Pull system
Not Provided:
 Six 200oz or better servos for ailerons
 Four 200oz or better servos for elevators
 Two or three servos for rudder equaling 800oz
 One throttle servo 70oz or better
 Ten 1.5” aluminum servo arms
 One or two 3” arms to tie rudder servos
 One 4” offset rudder servo arm
 One Fuel dot or other fueling device
 Some foam rubber for mounting receiver, ignition module, and fuel tank
Install all your flight control servos with the output shaft closest to the control surface.
 Install 6 200oz or better servos for the ailerons in the servo trays located in the bottom of the wings. Use
very high quality servos! These surfaces are huge and carry big loads!
 Install 4 200oz or better servos for the elevators in the servo trays located in the bottom of the horizontal
stabilizers.
 Install two or three equaling 800oz or better servos for the rudder in the servo tray inside the fuselage.
 Install your throttle and or choke servos in the forward bays provided.

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 First you need to find the pre-drilled holes for the steel posts. Install the aluminum control horn
assemblies to each surface with the M4 bolt in the down position. Use blue loc-tite on the aluminum
base to ensure the bolt does not try to back out under vibration. Screw on the horns on to the posts.
Do not use loc-tite installing the horn.
 Make sure your elevator servos are centered and mount your servo arms parallel to the hinge line.
 Take some masking tape and tape the elevator counter
balances to the stabilizers so that they are in a center
position.
 Screw in your two HD ball links onto the
counterclockwise ends of the 2.5” H9 push rods and
screw the other end into the control horn. Ensure
everything is still centered. Don’t forget to add
locknuts to the 4/40 bolts attaching the ball link to the
arm.
 Ensure aileron servos are centered and mount your
arms parallel to the hinge line.
 Be sure that you install the horns at the same height from the hinge line (see attached). By doing so you
will have very little servo matching to do afterwards.
 Screw in four HD ball links onto the counterclockwise ends of the 2.5” H9 push rods and screw the
other end into the control horn. Ensure everything is still centered. Don’t forget to add locknuts to the
4/40 bolts attaching the ball links to the arms.

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 Find the pre-drilled hard point, remove the covering and insert the longer 6” stainless treaded rod
provided and discard the 4” rod.
 Install the Dubro fasteners to the rod. Use loc-tite
as shown if you are not planning on using the lock
nuts.
 Now add the control horns placing them at 2-3/4”
centered from the hinge line.
 Ensure your rudder servo is centered and mount
your rudder servo arm.
 Two JR 8711 servos were used on our test
aircraft. You will need an additional servo arms
to tie the two or three servos together as well as a
servo matching devise.
 Install your pull-pull
cable using the 60lbs
leader provided. Please
discard the wire provided
with the Dubro pull-pull
set, as it is not strong
enough for a plane this
size. Cables should be
crossed to avoid any
rubbing on the exits. It is
normal for the non-
pulling side of the cable
to slacken a little when
the rudder is deflected.
 Install your tiller springs
you set aside earlier.
 Assemble the fuel tank according to the directions provided on the package. You will need to decide
whether you want a two or three-line setup. With a two-line setup you will need an additional “T”

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fitting in the carburetor line that connects to your fuel dot or fueling device. Make sure you use Tygon
fuel tubing inside the tank for the clunk as well.
 Install the fuel tank just in front of the wing tube using zip-ties or hook and latch (Velcro) straps. Place
a loop in the vent line over the top of the tank to prevent fuel loss during flight and improve flight times.
Take small zip-ties or fuel line clamps and fasten to all the points where the fuels lines connect.
 There are two switch locations already cut on each side of the fuse. They will both accept HD standard
switches. Mount your switches at this time.
 Install the fuel-filling device in a location of your choice. In this case, we installed it just behind the
ignition switch.
 Install your throttle push rod. Again as mentioned earlier, we do not want metal-to-metal contact at the
attachment point on the engine. Use a 4/40-rod with a 2/56 ball link for 4/40 rod to attach the push rod
to the motor.
 Once satisfied with your throttle setup, mount the cowl using the six 6/32 bolts provided and attach the
prop and spinner.
 Install the horizontal stabilizers at this time. Install the carbon fiber stabilizer tube. Slide in each half
and secure them with the four 4/40 retention bolts.

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 Install the horizontal stabilizers at this time. Install the carbon fiber stabilizer tube. Slide in each half
and secure them with four 6/32 retention bolts.
 Lets install the wings at this time and check our center of gravity (CG). Install the carbon fiber wing
tube. Slide in each wing panel and secure them with the four nylon wing retention bolts.
Tip#8 If the wing is tight you can coat the tube with a little baby powder to aid the insertion of the wing
panels.
Tip#9 For added protection in case the wing retention bolts back out during flight; you can add hitch pins to
the anti-rotation pins of the wing. With the wings installed, mark the anti-rotation pins ¼ inch from the
fuselage side. Remove the wings and drill a small hole in the anti-rotation pins. You can find appropriate
sized hitch pins at most local hardware stores. Re-install wings and insert the hitch pins for added
protection.
Now we’re ready to check the CG and install your remaining hardware. The CG range is 7-1/2 to 9” inches
back as measured where the wing meets the fuselage or center of wing tube. We recommend 8 inches for initial
flights.
 Check CG at this time and place your batteries and remaining hardware in locations to attain the desired
CG. If satisfied mount your remaining hardware.
Congratulations! You have just completed assembly of your Edge540 and or 540T. Now would be a good time
to install the optional vinyl graphics included with your kit.

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Chapter 9
Radio and Control Surface Setup
Now we are ready to setup your aircraft for flying. Included is this manual are templates for measuring surface
throw you may use if desired. We recommend that you setup your aircraft on low rates for initial flights until
you become familiar with the aircraft and its capabilities.
The recommended low rates for this aircraft are:
25 degrees for ailerons with 0 to 20% expo
15 degrees for elevators with 0 to 20% expo
30 degrees for rudder with 0 to 20% expo
The recommended high rates for this aircraft are:
35 degrees for ailerons with 40 to 70% expo
45 degrees for elevators with 40 to 70% expo
45 degrees for rudder with 30 to 70% expo
or as much as you can stand for hardcore flyers.
CG Range is 7-1/2 to 9 inches or center of tube.
Place an “×
××
×” to ensure task completion:
 What you will need in this chapter:
 Completed airframe
 Radio
 Throw templates or meter
 Cut out the templates for surface throw. These should be located on the last page of this manual.
 Tape each one in place using the horizontal line as a reference point to each stabilizer at the counter
balance and at the inside of the wings where the ailerons meet.
 Set your throws accordingly. Double check to make sure nothing is binding to include the throttle and
or choke servos and their linkages. Also, ensure all surfaces and controls are moving in the proper
directions.

20
Chapter 10
Final Inspection and Pre-Flight
Welcome to the final chapter prior to your maiden flight. We hope you have enjoyed building your Edge 540.
Lets go over the airframe and perform a pre-flight to make sure everything is in order.
 Inspect the airframe for any visible damage and loose covering that may have occurred during the build.
 Inspect the main landing gear and tail wheel assembly. Ensure all mounting hardware and collars are
fastened properly.
 Inspect your motor installation and cowl to ensure all bolts are tight and the muffler is firmly mounted in
place. Check the motor and muffler for possible contact with the cowl. Inspect ignition module and
spark plug wire for proper mounting. Check propeller and spinner to ensure they are both secure.
 Inspect the inside of the fuselage to ensure your batteries, switches, regulators (if equipped), fuel tank
and lines are securely fastened. Check nylon wing bolts to ensure they are in place and secured.
 Inspect all control surfaces and control surface hardware. Gently tug on each surface to make sure the
hinges are properly bonded. Check the four 4/40 horizontal stabilizer fasteners and ensure they’re in
place and secured.
 Check all servos for mounting screws. Check servo arm mounting screws and inspect that the 4/40 links
have been secured with lock nuts.
 Fill fuel tank and inspect for any leaks.
 Check your batteries in both your aircraft and radio to ensure they are fully charged
 Turn on radio to inspect all controls for binding, proper direction and throw while on high rates.
 Re-check CG. It should be anywhere from 7-1/2 to 9 (center of tube) inches depending on your flying
style.
 Secure aircraft using a buddy or hold down and start motor according to manufacturers guidelines.
Don’t forget to lower your throttle prior to ignition.
 Perform a proper range check with the motor running using your radio manufacturers instructions.
 Make sure you go back to low rates for your maiden takeoff and enjoy!
This concludes your pre-flight checks. After your maiden flight, repeat these steps to perform a post flight to
ensure nothing has loosened. It’s always a good habit to use a checklist like this one to go over your aircraft
prior to the first flight of the day.