Seagull Models 540 User manual

Kit features.
• Ready-made—minimal assembly & finishing required.
• Ready-covered covering.
• Photo-illustrated step-by-step Assembly Manual.
Made in Vietnam.
Specifications
Wingspan---------------------------------------- 68.2 in------------------------- 173.2cm.
Wing area--------------------------------------- 753sq.in-------------------- 48.6 sq.dm.
Approximate flying weight-------------------- 8.4-8.8lbs--------------------- 3.8-4kg.
Length-------------------------------------------- 60.6 in---------------------------- 154cm.
Recommended engine size-----------------.61- .91 cu.in---------------- 2-stroke.
.91-1.00 cu.in---------------- 4-stroke.
Radio System required 4 channel with 6 digital servos.
Flying skill level Intermediate/advanced.
Hand-made Almost Ready to Fly R/C Model Aircraft
ASSEMBLY MANUAL
EDGE 540

EDGE 540. Instruction Manual.
2
INTRODUCTION.
Thank you for choosing the EDGE 540 ARTF by SEAGULL MODELS. The EDGE 540 was designed
with the intermediate/advanced sport flyer in mind. It is a semi scale airplane which is easy to fly
and quick to assemble. The airframe is conventionally built using balsa, plywood to make it stronger
than the average ARTF , yet the design allows the aeroplane to be kept light. You will find that most
of the work has been done for you already.Flying the EDGE 540 is simply a joy.
This instruction manual is designed to help you build a great flying aeroplane. Please read this
manual thoroughly before starting assembly of your EDGE 540. Use the parts listing below to identify
all parts.
WARNING.
Please be aware that this aeroplane is not a toy and if assembled or used incorrectly it is
capable of causing injury to people or property. WHEN YOU FLY THIS AEROPLANE YOU
ASSUME ALL RISK & RESPONSIBILITY.
If you are inexperienced with basic R/C flight we strongly recommend you contact your R/C supplier
and join your local R/C Model Flying Club. R/C Model Flying Clubs offer a variety of training
procedures designed to help the new pilot on his way to successful R/C flight. They will also be able
to advise on any insurance and safety regulations that may apply.
ADDITIONAL ITEMS REQUIRED.
.61- .91 2-stroke engine.
.91-1.00 4-stroke engine.
Computer radio with six digital
servos.
Glow plug to suit engine.
Propeller to suit engine.
Protective foam rubber for radio
system.
Silicone fuel line.
TOOLS & SUPPLIES NEEDED.
Thick cyanoacrylate glue.
30 minute epoxy.
5 minute epoxy.
Hand or electric drill.
Assorted drill bits.
Modelling knife.
Straight edge ruler.
2mm ball driver.
Phillips head screwdriver.
220 grit sandpaper.
90° square or builder’s triangle.
Wire cutters.
Masking tape & T-pins.
Thread-lock.
Paper towels.
PARTS LISTING.
FUSELAGE ASSEMBLY
(1) Fuselage.
(1) Canopy hatch.
WING ASSEMBLY
(1) Right wing half with pre-installed
aileron.
(1) Left wing half with pre-installed
aileron.
(1) Aluminium dihedral brace.
Tail section assembly
(1) Horizontal stabilizer with pre-
installed elevator halves.
(1) Vertical stabilizer with pre-
installed rudder.
Some more parts.
HARDWARE PACK
COWLING
Landing gear.....

EDGE 540. Instruction Manual.
3
NOTE: To avoid scratching your new aero-
plane we suggest that you cover your
workbench with an old towel. Keep a
couple of jars or bowls handy to hold
the small parts after you open the
bags.
Please trial fit all parts. Make sure you
have the correct parts and that they
fit and are aligned properly before
gluing! This will ensure proper as-
sembly as the EDGE 540 is made
from natural materials and minor ad-
justments may have to be made.
The paint and plastic parts used in
this kit are fuel proof. However, they
are not tolerant of many harsh chemi-
cals including the following: paint
thinner, cyano-acrylate glue accel-
erator, cyanoacrylate glue de-bonder
and acetone. Do not let these chemi-
cals come in contact with the colours
on the covering and the plastic parts.

EDGE 540. Instruction Manual.
4
4)Deflect the aileron and completely
saturate each hinge with thin C/A glue. The
ailerons 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 lengh of the
aileron to the wing panel hinge line.
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 C/A glue.
1) Carefully remove the aileron from one
of the wing panels. Note the position of the
hinges.
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.
HINGING THE AILERONS.
Note:
The hinge is constructed of a special
material that allows the C/A to wick or
penetrate and distribute throughout the
hinge, securely bonding it to the wood
structure of the wing panel and aileron.
7) Repeat this process with the other wing
panel, securely hinging the aileron in place.
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.
5) Turn the wing panel over and deflect the
aileron in the opposite direction from the
opposite side. Apply thin C/A glue to each
hinge, making sure that the C/A penetrates into
both the aileron and wing panel.
6) Using C/A remover/debonder and a
paper towel, remove any excess C/A glue that
may have accumulated on the wing or in the
aileron hinge area.
Hinge.
T-pin.
C/A glue.
T-pin.
C/A glue.

EDGE 540. Instruction Manual.
5
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.
Work the aileron up and down several
times to “work in” the hinges and check
for proper movement.
1) Carefully remove the elevator from one
of the horizontal stabilizer panels. Note the
position of the hinges.
2) Remove each hinge from the horizontal
stabilizer panel and elevator and place a T-pin
in the center of each hinge. Slide each hinge
into the elevator until the T-pin is snug against
the elevator. This will help ensure an equal
amount of hinge is on either side of the hinge
line when the elevator is mounted to the
horizontal stabilizer panel.
1/64” gap or less will be maintained throughout
the lengh of the elevator to the horizontal
stabilizer panel hinge line.
The hinge is constructed of a special
material that allows the C/A to wick or
penetrate and distribute throughout the
hinge, securely bonding it to the wood
structure of the horizontal stabilizer panel
and elevator.
5) Turn the horizontal stabilizer panel over
and deflect the elevator in the opposite
direction from the opposite side. Apply thin CA
glue to each hinge, making sure that the C/A
penetrates into both the elevator and horizontal
stabilizer panel.
HINGING THE ELEVATORS.
3) Slide the elevator on the horizontal
stabilizer panel until there is only a slight gap.
The hinge is now centered on the horizontal
stabilizer panel and elevator. Remove the T-
pins and snug the elevator against the
horizontal stabilizer panel. A gap of 1/64” or
less should be maintained between the
horizontal stabilizer panel and elevator.
4)Deflect the elevator and completely
saturate each hinge with thin C/A glue. The
elevators front surface should lightly contact
the horizontal stabilizer during this procedure.
Ideally, when the hinges are glued in place, a
T-pins.
Hinges.
Note:
C/A glue.
Note:
C/A glue.

EDGE 540. Instruction Manual.
6
4)Deflect the rudder and completely
saturate each hinge with thin C/A glue. The
rudder front surface should lightly contact the
vertical fin during this procedure. Ideally, when
the hinges are glued in place, a 1/64” gap or
less will be maintained throughout the lengh
of the rudder to the fuselage panel hinge line.
1) Carefully remove the rudder from the
vertical fin. Note the position of the hinges.
2) Placing a T-pin in the center of each
hinge. Slide each hinge into the rudder until
the T-pin is snug against the rudder. This will
help ensure an equal amount of hinge is on
either side of the hinge line when the rudder is
mounted to the fuselage panel.
Note: The hinge is constructed of a special
material that allows the C/A to wick or
penetrate and distribute throughout the
hinge, securely bonding it to the wood
structure of the fuselage panel and rudder.
3) Slide the rudder on the vertical fin until
there is only a slight gap. The hinge is now
centered on the fuselage panel and rudder.
Remove the T-pins and snug the rudder
against the fuselage panel. A gap of 1/64” or
less should be maintained between the vertical
fin panel and rudder.
HINGING THE RUDDER.
8) After both elevator are securely hinged,
firmly grasp the horizontal stabilizer panel and
elevator to make sure the hinges are securely
glued and cannot be pulled out. Do this by
carefully applying medium pressure, trying to
separate the elevator from the horizontal
stabilizer panel. Use caution not to crush the
horizontal stabilizer structure.
Hinges.
Hinges.
T-pin.
C/A glue.
C/A glue.
6) Using C/A remover/debonder and a paper
towel, remove any excess C/A glue that may
have accumulated on the horizontal stabilizer
or in the elevator hinge area.
7) Repeat this process with the other
horizontal stabilizer panel, securely hinging the
elevator in place.

EDGE 540. Instruction Manual.
7
5) Turn the vertical fin panel over and deflect
the rudder in the opposite direction from the
opposite side. Apply thin C/A glue to each
hinge, making sure that the C/A penetrates into
the rudder and fuselage panel.
6) Using C/A remover/debonder and a paper
towel, remove any excess C/A glue that may
have accumulated on the fuselage or in the
rudder hinge area.
Note:Work the rudder left and right several
times to “work in” the hinges and check
for proper movement.
INSTALLING THE AILERON SERVOS.
Attach the string to the servo lead and
carefully thread it though the wing. Once you
have thread the lead throught the wing, remove
the string so it can use for the other servo
lead. Tape the servo lead to the wing to prevent
it from falling back into the wing.
We recommended to use long servos
arm for all servos without throttle servo.
Because the size of servos differ, you
may need to adjust the size of the precut
opening in the mount. The notch in the
sides of the mount allow the servo lead to
pass through.
Install the rubber grommets and brass
collets onto the aileron servo. Test fit the servo
into the aileron servo mount.
Install the servo into the servo tray.
Using a small weight (Weighted fuel pick-up
works well) and thread, feed the string through
the wing as indicated.
Secure the servos with the screws pro-
vided with your radio system.
Servo.
Small weight.
Thread.
C/A glue.
Wing bottom.
Thread.
Small weight.
Thread. Small weight.

EDGE 540. Instruction Manual.
8
AILERON LINKAGE.
INSTALLING THE AILERON LINKAGE.
1) Using a ruler & pen to draw a straight
line as below picture.
Install the aileron servo tray into the servo
mount.
Repeat the procedure for orther wing
haft.
Wing panel bottom.
Thread.
Electric wire.
Pull.
Plastic tape.
Aileron electric.
Pen.
Electric wire.
Thread.

EDGE 540. Instruction Manual.
9
4) Using a 1mm drill bit and the control
horns as a guide, drill the mounting holes
through the aileron halves.
5) Mount the control horns by inserting the
screws through the control horn bases and
aileron halves, then into the mounting
backplates. Do not overtighten the screws or
the backplates may crush the wood.
2) Locate the two nylon control horns, two
nylon control horn backplates and two ma-
chine screws.
Control Horn.
Mounting Screws. Mounting Plate.
3) Position the aileron horn on the bottom
side of aileron. The clevis attachment holes
should be positioned over the hinge line.
6) Thread one nylon adjustable control horn
onto each aileron control rod. Thread the
horns on until they are flush with the ends of
the control rods.
7) Pushrod assemble as same as pictures
below:
2mm x 30 mm.
2.8cm.
Pushrod.
Servo arm.
Straigh line.
M3 lock nut.

EDGE 540. Instruction Manual.
10
Battery.
4mm X 20mm.
1) Using a modeling knife, carefully cut
off the rear portion of one of the 3 nylon tubes
leaving 1/2” protruding from the rear of the
stopper. This will be the fuel pick up tube.
INSTALLING THE STOPPER ASSEMBLY.
FUEL TANK.
INSTALLING THE BATTERY.
ENGINE MOUNT.
Repeat the procedure for the other
aileron servo.
See pictures below:
C/A glue.
2) Using a modeling knife, cut one length
of silicon fuel line. Connect one end of the line
to the weighted fuel pick up and the other end
to the nylon pick up tube.
3) Carefully bend the second nylon tube
up at a 45º angle. This tube is the vent tube.

EDGE 540. Instruction Manual.
11
Important: When the stopper assembly is
installed in the tank, the top of the vent
tube should rest just below the top surface
of the tank. It should not touch the top of
the tank.
4) Test fit the stopper assembly into the
tank. It may be necessary to remove some of
the flashing around the tank opening using a
modeling knife. If flashing is present, make
sure none falls into the tank.
5) With the stopper assembly in place,
the weighted pick up should rest away from
the rear of the tank and move freely inside the
tank. The top of the vent tube should rest just
below the top of the tank. It should not touch
the top of the tank.
Attach the silicone fuel and pressure pipes
to the tank. The lower pipe is the ‘feed’ and the
upper two the ‘pressure and fill’. The fill pipe is
the next pipe.
You should mark which tube is the
vent and which is the fuel pickup when you
attach fuel tubing to the tubes in the
stopper. Once the tank is installed inside
the fuselage, it may be difficult to determine
which is which.
6) When satisfied with the alignment of
the stopper assembly tighten the 3mm x 20mm
machine screw until the rubber stopper ex-
pands and seals the tank opening. Do not
overtighten the assembly as this could cause
the tank to split.
Blow through one of the lines to en-
sure the fuel lines have not become kinked
inside the fuel tank compartment. Air
should flow through easily.
MOUNTING THE ENGINE.
 1) Install the pushrod housing through the
predrilled hole in the firewall and into the servo
compartment. The pushrod housing should
protrude 1/4" out past the front of the firewall.
Make a Z-Bend 1/4" from one end of the
plain wire pushrod.
Vent tube.
Fuel pick-up
tube. Fuel fill tube.
Vent tube. Fuel pick-up
tube.
Fuel fill tube.
Fuel tank.
Carefully use a lighter or heat gun to
permenently set the angle of the vent tube.

EDGE 540. Instruction Manual.
12
1) Assemble and mounting the wheel pants
as shown in the following pictures.
WHEEL AND WHEEL PANTS.
 6) Attach the Z-Bend in the pushrod wire
to the throttle arm on the carburetor. You will
need to remove the throttle arm from the car-
buretor to be able to attach the Z-bend. When
complete, reattach the throttle arm to the car-
buretor.
 5) Bolt the engine to the engine mount
using the four machine screws. Double cheek
that all the screws are tight before proceeding.
4.2mm
(4 pcs).
Pushrod wire.
4mm X 30mm.
4) Remove the engine. Using an drill bit,
drill the mounting holes through the engine
mount at the four locations marked.
 2) Place your engine onto the engine
mount. Adjust the engine is centered of the
edges of the engine case.
 3) When you are satisfied with the align-
ment, mark the locations of the engine
mounting.
125mm.

EDGE 540. Instruction Manual.
13
2) Follow diagram below for wheel pant
installation:
Wheel Collar.
Axle.
Wheel. Nut.
Wheel Pant.
Landing Gear.
Nut.
(2) Washer.
3) You have to trim each axle using a toll
cutting and cut-off wheel.
Caution when cutting the axles and
wear protective goggles.
10mm.
46mm.
(2) Wheel Collar.
Axle.
Wheel. Nut.
Nut.
(2) Washer.
Landing gear.

EDGE 540. Instruction Manual.
14
Because of the diameter of the cowl,
it may be necessary to use a needle
valve extension for the high speed needle
valve. Make this out of sufficient length
1.5mm wire and install it into the end of
the needle valve. Secure the wire in place
by tightening the set screw in the side of
the needle valve.
 2) While keeping the back edge of the
cowl flush with the marks, align the front of
the cowl with the crankshaft of the engine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening. Use the spinner backplate as a guide.
Hold the cowl firmly in place using pieces of
masking tape.
COWLING.
1) Slide the fiberglass cowl over the en-
gine and line up the back edge of the cowl with
the marks you made on the fuselage then trim
and cut.
1) The blind nuts for securing the landing
gear are already mounted inside the fuselage.
2) Using the hardware provided, mount the
main landing gear to the fuselage.
INSTALLING THE MAIN LANDING
GEAR.
4mm X 20mm.
Trim and cut.
Trim and cut.
 4) A drop of C/A glue on the wheel collar
screws will help keep them from coming lose
during operation.
Repeat the process for the other wheel.
3mmX10mm.

EDGE 540. Instruction Manual.
15
3) Slide the cowl back over the engine
and secure it in place using six 3mm x 10mm
wood screws. See picture below.
4) Install the muffler and muffler extension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
and fuel filler valve.
The propeller should not touch any
part of the spinner cone. If it does,
use a sharp modeling knife and carefully
trim away the spinner cone where the pro-
peller comes in contact with it.
 1) Install the spinner backplate, propeller
and spinner cone. The spinner cone is held in
place using two 3mm x 15mm wood screws.
(spinner is not included).
INSTALLING THE SPINNER.
1.5mm wire
(needle valve).
3mm X 10mm
(6pcs).

EDGE 540. Instruction Manual.
16
 3) Slide the stabilizer into place in the pre-
cut slot in the rear of the fuselage. The stabi-
lizer should be pushed firmly against the front
of the slot.
 4) With the stabilizer held firmly in place,
use a pen and draw lines onto the stabilizer
where it and the fuselage sides meet. Do this
on both the right and left sides and top and
bottom of the stabilizer.
 5) Remove the stabilizer. Using the lines
you just drew as a guide, carefully remove the
covering from between them using a model-
ing knife.
2) Install the rubber grommets and brass
collets onto the elevator and rudder servo. Test
fit the servo into the aileron servo mount.
3) Secure the servos with the screws pro-
vided with your radio system.
Because the size of servos differ, you may
need to adjust the size of the precut opening
in the mount. The notch in the sides of the
mount allow the servo lead to pass through.
HORIZONTAL STABILIZER.
2) Using a modeling knife, carefully re-
move the covering at mounting slot of horizon-
tal stabilizer ( both side of fuselage).
1) Using a ruler and a pen, locate the
centerline of the horizontal stabilizer, at the trail-
ing edge, and place a mark. Use a triangle
and extend this mark, from back to front,
across the top of the stabilizer. Also extend
this mark down the back of the trailing edge of
the stabilizer.
Left side.
Elevator servo.
Right side.
Elevator
servo. Rudder servo.
Center line.
Remove covering.
Pen.
1) Locate and cut out the covering film from
the servo holes in both sides of fuselage.
ELEVATOR - RUDDER SERVO
INSTALLATION.
Remove covering.

EDGE 540. Instruction Manual.
17
When cutting through the covering
to remove it, cut with only enough pres-
sure to only cut through the covering it-
self. Cutting into the balsa structure may
weaken it.
 6) Using a modeling knife, carefully re-
move the covering that overlaps the stabilizer
mounting platform sides in the fuselage. Re-
move the covering from both the top and the
bottom of the platform sides.
 7) When you are sure that everything is
aligned correctly, mix up a generous amount
of 30 Minute Epoxy. Apply a thin layer to the
top and bottom of the stabilizer mounting area
and to the stabilizer mounting platform sides
in the fuselage. Slide the stabilizer in place
and realign. Double check all of your mea-
surements once more before the epoxy cures.
Hold the stabilizer in place with T-pins or mask-
ing tape and remove any excess epoxy using
a paper towel and rubbing alcohol.
VERTICAL STABILIZER
INSTALLATION.
1) Using a modeling knife, remove the
covering from over the precut hinge slot cut
into the lower rear portion of the fuselage. This
slot accepts the lower rudder hinge.
 8) After the epoxy has fully cured, re-
move the masking tape or T-pins used to hold
the stabilizer in place. Carefully inspect the
glue joints. Use more epoxy to fill in any gaps
that may exist that were not filled previously
and clean up the excess using a paper towel
and rubbing alcohol.
2) Slide the vertical stabilizer into the slot
in the top of the fuselage. The rear edge of
the stabilizer should be flush with the rear edge
of the fuselage and the lower rudder hinge
should engage the precut hinge slot in the
lower fuselage. The bottom edge of the stabi-
lizer should also be firmly pushed against the
top of the horizontal stabilizer.
Remove covering.
Covered wood
filler piece.
Hinge.
Hinge slot.
Remove covering.

EDGE 540. Instruction Manual.
18
6) When you are sure that everything is
aligned correctly, mix up a generous amount of
Flash 30 Minute Epoxy. Apply a thin layer to the
mounting slot in the top of the fuselage and to
the sides and bottom of the vertical stabilizer
mounting area. Apply epoxy to the bottom and
top edges of the filler block and to the lower
hinge also. Set the stabilizer in place and re-
align. Double check all of your measurements
once more before the epoxy cures. Hold the
stabilizer in place with T-pins or masking tape
and remove any excess epoxy using a paper
towel and rubbing alcohol. Allow the epoxy to
fully cure before proceeding.
CONTROL HORN INSTALLATION.
 1) Locate the two nylon control horns, two
nylon control horn backplates and four
machine screws.
3) While holding the vertical stabilizer
firmly in place, use a pen and draw a line on
each side of the vertical stabilizer where it
meets the top of the fuselage.
4) Remove the stabilizer. Using a mod-
eling knife, remove the covering from below
the lines you drew. Also remove the covering
from the bottom edge of the stabilizer and the
bottom and top edges of the filler block. Leave
the covering in place on the sides of the filler
block.
When cutting through the covering to
remove it, cut with only enough pressure
to only cut through the covering itself. Cut-
ting into the balsa structure may weaken
it.
5) Slide the vertical stabilizer back in
place. Using a triangle, check to ensure that
the vertical stabilizer is aligned 90º to the hori-
zontal stabilizer.
90º
Vertical
Stabilizer.
Horizontal
Stabilizer.
Pen.
Remove covering.
C/A glue.

EDGE 540. Instruction Manual.
19
 2) Position the elevator horn on the both
side of elevator. The clevis attach- ment holes
should be positioned over the hinge line.
Control Horn.
Mounting Screws. Mounting Plate.
 3) Using a 1.5mm drill bit and the control
horns as a guide, drill the mounting holes
through the elevator halves.
4) Mount the control horns by inserting the
bolts through the control horn bases and
elevator halves, then into the mounting
backplates. Do not overtighten the nuts or the
backplates may crush the wood.
5) Position the rudder control horn on the
left side of the airplane. Mount the control horn
parallel with the horizontal stabilizer.
 6) Install the rudder control horn using the
same method as with the elevator control
horns.
Elevator - rudder pushrods assembly follow
pictures below.
ELEVATOR-RUDDER PUSHROD
INSTALLATION.
2mm x 20 mm.
11.8cm.
Rudder pushrod.
Elevator pushrod.
10.8cm.
Elevator control horn.
C/A glue.
Left side.
Elevator control horn.
Rudder control horn.

EDGE 540. Instruction Manual.
20
MOUNTING THE TAIL WHEEL BRACKET.
MOUNTING THE CONTROL CLASP.
See pictures below:
 1) Set the tail wheel assembly in place on
the plywood plate. The pivot point of the tail
wheel wire should be even with the rudder
hinge line and the tail wheel bracket should
be centered on the plywood plate.
 2 Using a pen, mark the locations of the
two mounting screws. Remove the tail wheel
bracket and drill 1mm pilot holes at the loca-
tions marked.
 3) Secure the tail wheel bracket in place
using two 3mm x 12mm wood screws. Be
careful not to overtighten the screws.
INSTALLING TAIL STRUT SYSTEM.
Tail strut system assembly follow pictures
below.
Control clasp.
2 screws.
2mm X 20mm.
3.2mm drill bit.
Right side.