Seagull Models EDGE 540 User manual

Kit features.
• Ready-made—minimalassembly&finishingrequired.
• Ready-coveredcovering.
• Photo-illustratedstep-by-stepAssemblyManual.
EDGE 540
MadeinVietnam.
Specifications
Wingspan----------------------------------------77.5in----------------------------197cm.
Wing area--------------------------------------- 1023sq.in--------------------- 66 sq.dm.
Approximate flying weight------------------ 10.6-13lbs------------------- 4.8-5.8kg.
Length--------------------------------------------71in-------------------------------179cm.
Recommended engine size--------------- 1.60 cu.in---------------------- 2-stroke.
1.80 cu.in--------------- 4-stroke.
Radio System required 6 channel with 6 digital servos - 6.5kg/cm.
Flying skill level Intermediate/advanced.
2.
“Graphics and specfications may change without notice”.
MS: 26
Hand-made Almost Ready to Fly R/C Model Aircraft
ASSEMBLY MANUAL

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
easytoflyandquicktoassemble.Theairframeisconventionallybuiltusingbalsa,plywood tomake
itstrongerthantheaverageARTF,yetthedesignallowstheaeroplanetobekeptlight.Youwillfind
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
manualthoroughlybeforestartingassemblyofyour EDGE540.Usethepartslistingbelowtoidentify
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
supplierandjoinyourlocalR/CModelFlyingClub.R/CModelFlyingClubsofferavarietyoftraining
proceduresdesignedtohelpthenewpilotonhiswayto successful R/C flight. They will also be able
to advise on any insurance and safety regulations that may apply.
ADDITIONAL ITEMS REQUIRED.
1.60 2-stroke engine.
1.80 4-stroke engine.
Computer radio with digital servos -
6.5kg/cm.
Glow plug to suit engine.
Propeller to suit engine.
Protective foam rubber for radio
system.
Siliconefuel line.
TOOLS & SUPPLIES NEEDED.
Thick cyanoacrylate glue.
30 minute epoxy.
5 minute epoxy.
Hand or electric drill.
Assorted drill bits.
Modellingknife.
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 / aileron.
(1) Left wing half / aileron.
(2) Aluminium dihedral brace.
Tail section assembly
(2) Horizontal stabilizer / elevator
halves.
(1) Rudder halves
Some more parts.
HARDWAREPACK
COWLING
Landinggear.....

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NOTE:To avoid scratching your new aero-
planewesuggestthatyoucoveryour
workbench with an old towel. Keep a
couple of jars or bowls handy to hold
the small parts after you open the
bags.
Pleasetrialfitallparts.Makesureyou
havethecorrectpartsandthattheyfit
andarealignedproperlybeforegluing!
This will ensure proper assembly as
the EDGE 540 is made from natural
materialsandminoradjustmentsmay
have to be made.
The paint and plastic parts used in
this kit are fuel proof. However, they
arenottolerantofmanyharshchemi-
cals including the following: paint
thinner, cyano-acrylate glue accel-
erator,cyanoacrylategluede-bonder
andacetone.Donot let thesechemi-
calscome incontact withthe colours
onthecoveringand the plasticparts.
4)Deflect the aileron and completely
saturate each hinge with thin C/A glue. The
aileronsfrontsurfaceshould 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, areprehinged
with hinges installed, but the hinges are not
gluedinplace.Itisimperativethatyouproperly
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)Removeeach hinge from thewingpanel
and aileron and place a T-pin in the center of
each hinge. Slide each hinge into the aileron
untiltheT-pin issnug againstthe aileron.This
will help ensure an equal amount of hinge is
oneithersideofthehingelinewhentheaileron
is mounted to the wing panel.
HINGING THE AILERONS.
Note:
The hinge is constructed of a special
materialthatallowstheC/Atowickorpenetrate
and distribute throughout the hinge, securely
bonding it to the wood structure of the wing
paneland aileron.
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
shouldbe maintained betweenthe wing panel
andaileron.
Hinge.
T-pin.
Hinge.
T-pin.
C/Aglue.
Hinge.

EDGE 540. Instruction Manual.
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8)Afterbothailerons are securelyhinged,
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.
HINGING THE ELEVATORS.
Glue the elevator hinges in place using the
same tectniques used to hinge the ailerons.
HINGING THE RUDDER.
Glue the rudder hinges in place using the
same tectniques used to hinge the ailerons.
INSTALLING THE AILERON SERVOS.
We recommended to use long servos arm
for all servos without throttle servo.
Using a small weight (Weighted fuel pick-up
workswell) and thread, feedthestring through
the wing as indicated.
Thread.
Small weight.
Wing bottom.
7) Repeat this process with the other wing
panel, securely hinging the aileron in place.
5)Turnthewing paneloverand deflect the
aileron in the opposite direction from the
opposite side. Apply thin C/A glue to each
hinge,makingsure that the C/Apenetratesinto
both the aileron and wing panel.
6) Using C/A remover/debonder and a
papertowel, remove anyexcessC/A glue that
may have accumulated on the wing or in the
aileronhinge area.
String.
Small weight.
Install the rubber grommets and brass
collets onto the aileron servo. Test fit the
servo into the aileron servo mount.
Because the size of servos differ, you
mayneedtoadjust the size of theprecutopen-
ing in the mount. The notch in the sides of
themountallowtheservoleadtopassthrough.
Hinge. C/Aglue.
Servo.
Small weight.
Thread.

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Attach the thread to the servo lead and
carefully thread it though the wing. Once you
havethreadthe leadthroughtthewing,remove
the string so it can use for the other servo
lead.Tapethe servo lead tothewingtoprevent
it from falling back into the wing.
Secure the servos with the screws pro-
vided with your radio system.
Repeat the procedure for the other wing
half.
ENGINE MOUNT.
See pictures below ( Engine mount do not
include ) :
Mark and drill 4 holes for engine mount.
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.
2) Usinga modeling knife, cut onelength
ofsiliconfuel line. Connect oneend of theline
tothe weighted fuel pick up andthe 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.
INSTALLING THE STOPPER ASSEMBLY.
FUEL TANK.
4x30mm.
Thread locker glue.
Electric wire.
Thread.
Wing bottom.

EDGE 540. Instruction Manual.
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Carefully use a lighter or heat gun to
permenently set the angle of the vent tube.
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.
Attach the silicone fuel and pressure pipes
tothetank. The lowerpipeis the ‘feed’andthe
uppertwo the ‘pressureand fill’. Thefill pipeis
the next pipe.
5) With the stopper assembly in place,
the weighted pick up should rest away from
therear 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.
6) When satisfied with the alignment of
the stopper assembly tighten the 3 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.
Fueltank.
Rubber band.
Venttube. Fuel pick up
tube.
Fuel fill tube.
You should mark which tube is the vent
and which is the fuel pick up when you attach
fuel tubing to the tubes in the stopper. Once
thetank is installed inside thefuselage, itmay
be difficult to determine which is which.
Silicon tubing not inclued.

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Vent tube.
Fuelfill tube.
Fuel pick up
tube.
2) Follow diagram below for wheel pant
installation:
WheelCollar.
Axle.
Wheel. Nut.
Wheel Pant.
LandingGear.
Nut.
Plywood Washer.
1) Assembling and mounting the wheel
pants as shown below pictures.
Blow through one of the lines to ensure
the fuel lines have not become kinked inside
the fuel tank compartment. Air should flow
through easily.
WHEEL AND WHEEL PANTS.
Plywood Washer.
Cautionwhen cuttingthe axlesand wear
protective goggles.
3) You have to trim each axles and using a
tool cutting and cut-off wheel.
57mm.
14mm.
7mm.
Plywoodwasher.
Threadlocker.

EDGE 540. Instruction Manual.
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4) A drop of Thread locker glue on the
wheel collar screws will help keep them from
coming lose during operation.
Repeat the process for the other
wheel.
1) The blind nuts for securing the landing
gearare already mountedinside the fuselage.
2) Usingthe hardware provided, mount the
main landing gear to the fuselage.
INSTALLING THE FUSELAGE SERVO.
Engine 2 stroke.
Engine 4 stroke.
C/Aglue.
Rudder
servo.
Throttle servo.
Servo tray.
INSTALLING THE MAIN LANDING
GEAR.
1) Locate and cut out the covering film
fromthe servo holesin bothsides of fuselage.
ELEVATOR SERVO INSTALLATION.
6mm X 20mm.
Throttle servo.
Rudder servo.
Landinggear.

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2) Installthe rubber grommets and brass
collets onto the elevator servo. Test fit the
servo into the elevator servo mount.
Left side.
Remove
covering.
Because the size of servos differ, you
mayneedtoadjustthesizeofthe precut open-
ing in the mount. The notch in the sides of the
mount allow the servo lead to pass through.
Left side.
Elevator servo.
Rightside.
Elevator servo.
 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.
MOUNTING THE ENGINE.
1) Install the pushrod housing through the
predrilledholein the firewallandintothe servo
compartment. The pushrod housing should
protrude 1/4" out past the front of the firewall.
MakeaZ-Bend 1/4" fromoneend of theplain
wire pushrod.
3)Secure theservos with the screws pro-
vided with your radio system.
4) Remove the engine. Using an drill bit,
drill the mounting holes through the engine
mount at the four locations marked.
 6) AttachtheZ-Bendin the pushrodwire to
thethrottlearmonthe carburetor.Youwillneed
toremovethethrottlearmfromthecar-buretor
to be able to attach the Z-bend. When
complete,re-attach the throttlearm to the car-
buretor.
 5) Bolttheenginetotheengine mountusing
the four machine screws. Double check that
all the screws are tight before proceeding.
Engine 2 stroke.
4.2mm.
150mm.
4x30mm.

EDGE 540. Instruction Manual.
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 2) While keeping the back edge of the
cowl flush with the marks, align the front of
thecowlwiththecrankshaftoftheengine. The
front of the cowl should be positioned so the
crankshaft is in nearly the middle of the cowl
opening.Usethespinnerbackplate as a guide.
Hold the cowl firmly in place using pieces of
masking tape.
COWLING.
1) Slide the fiberglass cowl over the en-
gineandline up thebackedge of the cowlwith
themarks you made on thefuselage thentrim
and cut.
3) Slide the cowl back over the engine
andsecureitinplaceusingsix3x10mmwood
screws. See picture below.
4) Installthemufflerandmufflerextension
onto the engine and make the cutout in the
cowl for muffler clearance. Connect the fuel
and pressure lines to the carburetor, muffler
andfuel filler valve.
Thread locker.
Pushrod
wire.
Engine 4 stroke.
Trim and cut.
3x10mm.
1.5mm wire
(needlevalve).
Because of the diameter of the cowl, it
may be necessary to use a needle valve ex-
tensionforthehigh speed needle valve. Make
thisout of sufficient length 1.5mmwire andin-
stall it into the end of the needle valve. Se-
cure the wire in place by tightening the set
screw in the side of the needle valve.

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3x10mm(6pcs).
INSTALLING THE SWITCH.
Installthe switch intotheprecut hole inthe
side of the fuselage.
 1) Install the spinner backplate, propeller
and spinner cone. (spinner is not included).
INSTALLING THE SPINNER.
Switch.
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 propeller comes in
contact with it. Remove covering.

EDGE 540. Instruction Manual.
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4) Slide the two horizontal fin halves
together and carefully align them at the
possition on the fuselage. Wipe away any
excess epoxy using paper towels.
 5) Bolt the horizontal fin to the fuselage
using the 4 machine screws (3x10mm).
Double cheek that all the screws are tight
beforeproceeding.
VERTICAL STABILIZER INSTALLATION.
2)Sand the aluminium tube using
sandpaper. This will improve the bond of the
epoxy to the cardboard horizontal fin.
Coatboth sidesof one halfof thealuminium
tube with 30 minute epoxy. Next, pour some
epoxy into the cardboard horizontal fin. Use
enough epoxy to fill any gaps.
3) Insert aluminiumtubeinto thecardboard
of fuselage.
Remove
covering.
1) Using a modeling knife, remove the
covering from over the precut hinge slot cut
intothelowerrearportionofthefuselage. This
slot accepts the lower rudder hinge.
2) Slidethe vertical stabilizer into theslot
in the top of the fuselage. The rear edge of
thestabilizer shouldbe flushwiththerearedge
INSTALLING HORIZONTAL FIN.
1)Remove the coveringat the reartail root
of horizontal fin as picture shown below.
Hinge.
3x10mm.

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4) Remove the stabilizer. Using a model-
ing knife, remove the covering from below the
lines you drew.
5) Slide the vertical stabilizer back in
place. Using a triangle, check to ensure that
thevertical stabilizer is aligned 90ºto the hori-
zontal stabilizer.
90º Vertical
Stabilizer.
Horizontal
Stabilizer.
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.
of the fuselage and the lower rudder hinge
should engage the precut hinge slot in the
lowerfuselage. The bottom edge of thestabi-
lizer should also be firmly pushed against the
top of the horizontal stabilizer.
Remove
covering.
pen.
C/Aglue.
Hinge.
When cutting through the covering to re-
moveit, cut with only enough pressure toonly
cut through the covering itself. Cutting into
the balsa structure may weaken it.
6) When you are sure that everything is
alignedcorrectly,mix up a generous amount of
30MinuteEpoxy. Applyathinlayertothemount-
ingslotinthetopofthefuselageandtothesides
and bottom of the vertical stabilizer mounting
area. Applyepoxy tothebottomandtop edges
of the filler block and to the lower hinge also.
Set the stabilizer in place and realign. Double
checkallofyour measurements once morebe-
foretheepoxycures.Holdthestabilizerinplace
with T-pins or masking tape and remove any
excess epoxyusing a paper toweland rubbing
alcohol. Allow the epoxy to fully cure before
proceeding.

EDGE 540. Instruction Manual.
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 1) Aileron control horn:
Mix a small amount of 30 minute epoxy and
lightly coat the inside of the hole in the aileron
and the 3x50mm control horn screw.
 2) Thread the screw (insert the washer)
intothe holefromthetopofsurface.Wipeaway
any excess epoxy on the wing and screw with
rubbing alcohol and a paper towel. Screw the
M3 nut (insert the washer) in place as shown.
Alllow the epoxy to fully cure.
Wing.
Aileron.
Repeat the procedure for orther
elevator.
ELEVATOR PUSHROD INSTALLATION.
Elevator pushrods assembly follow pictures
below.
Aluminiumwasher.
M3 nut.
M3 lock nut.
Wing bottom.
M3control horn.
Wing bottom.
Aileroncontrol horn.
Center the servo using the radio system.
Attach the servo arm to the servo using the
screw provided with the servo.
Elevator control horn.
Horizontalfin. Elevator.
Pushrod L= 138mm .
AILERONCONTROLHORN INSTALLATION.
3x50mm.
Repeat the procedure for orther wing.
ELEVATORCONTROLHORNINSTALLATION.
Repeat the procedure for the elevator control
horn as same as the way of aileron control horn.
Metalclevis.
M lock.
3

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Repeat the procedure for orther
aileron.
See pictures below:
RUDDER CONTROL HORN
INSTALLATION.
RUDDER PULL - PULL CABLE SYSTEM.
Rudder control horn:
Usingthesametectniquesused aileron control
horn. See picture below.
Repeat the procedure for orther
elevator.
Repeat the procedure for wing panel as
same as elevator pushrod.
AILERON PUSHROD INSTALLATION.
M3lock nut.
Rudder
control horn.
Elevator pushrod.
Pushrod L= 125mm .
Metalclevis.
veticalfin.

EDGE 540. Instruction Manual.
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 2) With the radio on, check the operation
of the rudder. Adjust the cables so when the
rudder servo is centered, the rudder is
centered as well. There will be tension on the
cables.Adjustmentscanbemadeattherudder
control horn and at the servo arm. Once
adjustments are made, secure the servo arm
to the rudder arm servo using the screw that
came with the servo
MOUNTING THE TAIL WHEEL.
See picture below
M3 x20 mm.
Cable.
Right side.
M3 x20 mm.
Rudder.
 1) Insert servo arm into servo.
Cable wire.
Cable. Metalclevis.
Control horn.
Pushrod.

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1) Plug the servo leads and the switch
lead into the receiver. Plug the battery pack
lead into the switch also.
2) Wrap the receiver and battery pack in
the protective foam rubber to protect them
from vibration.
INSTALLING THE BATTERY-RECEIVER.
 3) Routethe antennain the antennatube
inside the fuselage and secure it to the bot-
tom of fuselage using a plastic tape. See pic-
ture below.
Tie wrap.
Receiver.
Battery.
Insert two wing panels as pictures below:
ATTACHMENT WING-FUSELAGE.
Attach the aluminium tube into fuselage.
THROTTLE SERVO ARM
INSTALLATION.
1) Install adjustable servo connector in
the servo arm.
Throttle.
Antennawire.
AdjustableServo
connector.
Servoarm.
Antenna.
 2) Install the pushrod throttle.

EDGE 540. Instruction Manual.
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Wing bolt.
It is critical that your airplane be balanced
correctly. Improper balance will cause your
planeto lose control and crash. The center of
gravity is located 95-110mm back from the
leading edge of the wing, measured at the
Wing Tip.
BALANCING.
CONTROL THROWS.
1) We highly recommend setting up the
EDGE 540 using the control throws listed at
right. We have listed control throws for both
Low Rate (initial test flying/sport flying) and
High Rate (aerobatic flying).
 3) When the elevator, rudder and aileron
control surfaces are centered, use a ruler and
check the amount of the control throw in each
surface. The control throws should be
measured at the widest point of each sur-
face!
2) Turn on theradio system,and withthe
trim tabs on the transmitter in neutral, center
the control surfaces by making adjustments
totheclevisesor adjustable servoconnectors.
The servo arms should be centered also.
INITIALFLYING/SPORT FLYING
Ailerons: 3/16” up 3/16” down
Elevator : 3/8” up 3/8” down
Rudder : 3/4 right 3/4 left
Ailerons: 3/8” up 3/8” down
Elevator : 7/8” up 7/8” down
Rudder : 1-1/4” right 1-1/4” left
Do not use the aerobatic settings for
initialtest flying or sport flying.
AEROBATIC FLYING
Wing bolt.
95 - 110mm.

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PREFLIGHT CHECK.
1) Completely charge your transmitter
and receiver batteries before your first day of
flying.
2) Check every bolt and every glue joint
in the EDGE 540 to ensure that everything is
tight and well bonded.
3) Double check the balance of the air-
plane. Do this with the fuel tank empty.
 4) By moving the position of the adjust-
able control horn out from the control surface,
you will decrease the amount of throw of that
control surface. Moving the adjustable con-
trol horn toward the control surface will in-
crease the amount of throw.
4) Checkthe control surfaces. All should
move in the correct direction and not bind in
any way.
5) If your radio transmitter is equipped
withdual rate switchesdouble check thatthey
are on the low rate setting for your first few
flights.
6) Check to ensure the control surfaces
are moving the proper amount for both low
and high rate settings.
8) Properlybalance the propeller. An out
of balance propeller will cause excessive vi-
bration which could lead to engine and/or air-
frame failure.
We wish you many safe and enjoyable
flights with your EDGE 540.
7) Check the receiver antenna. It should
be fully extended and not coiled up inside the
fuselage.
 A) Check the operation and direction of
the elevator, rudder, ailerons and throttle.
 B) Plug in your radio system per the
manufacturer's instructions and turn every-
thingon.
 C) Check the elevator first. Pull back on
theelevator stick. The elevator halves should
move up. If it they do not, flip the servo re-
versing switch on your transmitter to change
the direction.
 D) Check the rudder. Looking from be-
hindthe airplane, move the rudder stick tothe
right. Theruddershould move totheright. If it
does not, flip the servo reversing switch on
your transmitter to change the direction.
FLIGHT PREPARATION.
 E)Check the throttle. Moving the throttle
stick forward should open the carburetor bar-
rel. Ifitdoesnot,fliptheservoreversingswitch
on your transmitter to change the direction.
 F) From behind the airplane, look at the
aileronontheright wing half. Movetheaileron
sticktotheright. Therightaileronshouldmove
upandthe otheraileronshould move down. If
it does not, flip the servo reversing switch on
your transmitter to change the direction.