Hangar 9 EDGE 540 User manual

ASSEMBLY MANUAL

Specifications

Wingspan: .............. 97.5 in (2476.5mm)

Length: ................... 85 in (2159mm)

WingArea: ............ 1730.6 sq in (111.65 sq dm)

Weight:................... 22.5–25.5 lb (10.2 kg–11.5 kg)

Radio: ..................... 4-channel w/8 servos

Engines: ...................3.8–4.8 cu in

Edge 540

WE GET PEOPLE FLYING

• Superior controllability and aerobatic flight characteristics

• Lightweight construction

• Designed by veteranTOC competitor Mike McConville

• 90% built 1/3-scaleARF

• Plug-in wings and stabilizers for easy transport and field assembly

Table of Contents

Using the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Other Items Needed (not included in the kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Additional Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Contents of Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Additional Required Tools and Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Servo Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Before Starting Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Section 1 – Aileron Servo Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Section 2 – Aileron Control Horn Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Section 3 – Hinging and Sealing the Control Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Section 4 – Sealing the Hinge Gaps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Section 5 – Aileron Linkage Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Section 6 – Wing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Section 7 – Elevator Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Section 8 – Rudder Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Section 9 – Landing Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Section 10 – Wheel Pant Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Section 11 – Tail Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Section 12 – Receiver, Battery and Fuel Tank Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Section 13 – Mounting the Engine and Cowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Section 14 – Hatch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Section 15 – Balancing the Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Section 17 – Control Throws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Section 16 – Radio Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Preflight at the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

2004 Official AMA National Model Aircraft Safety Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Using the Manual

This manual is divided into sections to help make assembly easier to understand and to provide breaks between

each major section. Remember to take your time and follow the directions.

Covering Colors

• Flame Red HANU883 • Pearl Blue HANU845

• Silver HANU881 • White HANU870

Contents of Kit

Large Parts

A. Fuselage w/Hatch HAN1151

B. Canopy Hatch HAN1158

C. Right Wing Panel w/Aileron HAN1152

D. Left Wing Panel w/Aileron HAN1153

E. Right Stabilizer w/Elevator HAN1154

F. Left Stabilizer w/Elevator HAN1155

G. Rudder HAN1156

H. Canopy HAN1157

I. Painted Cowl HAN1159

J. Carbon Fiber Landing Gear HAN1160

K. Wheel Pants HAN1161

L. Anodized Wing Tube HAN1164

Additional Required Equipment

Radio Equipment

• 6-channel radio system (minimum)

• 1 standard servo for throttle (JRPS537

recommended or equivalent)

• 7 hi-torque servos (JRPS8411

recommended or equivalent)

• 1 hi-torque servo (JRPS8611

recommended or equivalent)

Recommended JR®Systems

• PCM10X

• XP8103

• X-378

• XP662

• XF631

Recommended Engines

•G-62, GT-80

JR XP8103

JR PCM 10X

Zenoah®GT-80

ZENE80T

Zenoah®G62

ZENE62A

Other Items Needed (not included in the kit)

• Propeller (consult engine instructions)

• 12" Servo Extension (JRPA098)

• 18" Servo Extensions (JRPA099) (3)

• 24" Servo Extensions (JRPA102) (5)

• Y-Harness (JRPA133) (2)

• MatchBox™ (JRPA900) (2)

• Zenoah®2" Prop Drive (ZEN20004)(GT-80 only)

Items not shown:

Landing Gear Fairing HAN1162

Decal Set HAN1163

Anodized Stabilizer Tubes HAN1165

Additional Required Tools and Adhesives

Tools

• 4-40 tap

• 8-32 tap

• Adjustable wrench (small)

• Canopy scissors

• Drill (drill press preferred)

• Drill bit: 1/16", 3/32", 7/32", 1/4", #43, 1/2",

5/32", 9/64"

• Drum sander

• Cut-off wheel

• Velcro straps

• Flat blade screwdriver w/short handle

• Foam: 1/2"

• Hex wrench: 3/32"

• Hobby knife

• Masking tape

• Phillips screwdriver (small)

• Pliers

• Scissors

• Square

• Syringe

• Tap handle

• Toothpicks

Adhesives

• 6-minute epoxy

• 30-minute epoxy

• Thick CA (cyanoacrylate) glue

• CA remover/debonder

• Pacer Z-42 Threadlock

• Formula 560-canopy glue

• Shoo Goo

Other Required Items

• Epoxy brushes

• Felt-tipped pen or pencil

• File

• Measuring device (e.g. ruler, tape measure)

• Mixing sticks for epoxy

• Paper towels

• Petroleum jelly

• Rubbing alcohol

• Sanding bar

• Sandpaper (coarse)

• Clear UltraCote® (HANU964)

• Covering Iron (HAN101)

• Dental floss or string

HD 1/2 Servo Arm 4-40: JR (8) HAN3574

3D XL 1/2 Servo Arm 4-40: JR (1) HAN3578

8-32 Swivel Clevis Horn (4) HAN3614

4-40 x 4-40 HD Ball Link (5) HAN3616

Tailwheel, Lg Haigh 12-22 lb (1) OHI160

Super Hinge Points (4) ROB309

Dura-Collars, 3/16" (1) DUB141

Axle Shafts, 3/16 x 2" (1) DUB249

Fuel Tank, 32oz (1) DUB690

Pro-Lite Wheels, 3-1/2" (1) HAN308

Titanium Pro-Links 4-40 x 2-1/2" (1) HAN3552

Titanium Pro-Links 4-40 x 3-1/2" (1) HAN3554

Titanium Pro-Links 4-40 x 4-1/2" (1) HAN3556

Before Starting Assembly

Before beginning the assembly of the Edge 540, remove each part from its bag for inspection. Closely inspect

the fuselage, wing panels, rudder, and stabilizer for damage. If you find any damaged or missing parts, contact

the place of purchase.

If you find any wrinkles in the covering, use a heat gun or covering iron to remove them. Use caution while

working around areas where the colors overlap to prevent separating the colors.

Warranty Information

Horizon Hobby, Inc. guarantees this kit to be free from defects in both material and workmanship at the date of

purchase. This warranty does not cover any parts damage by use or modification. In no case shall Horizon

Hobby's liability exceed the original cost of the purchased kit. Further, Horizon Hobby reserves the right to

change or modify this warranty without notice.

In that Horizon Hobby has no control over the final assembly or material used for the final assembly, no liability

shall be assumed nor accepted for any damage of the final user-assembled product. By the act of using the

product, the user accepts all resulting liability.

Once assembly of the model has been started, you must contact Horizon Hobby, Inc. directly regarding any

warranty question that you have. Please do not contact your local hobby shop regarding warranty issues, even if

that is where you purchased it. This will enable Horizon to better answer your questions and service you in the

event that you may need any assistance.

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.

Horizon Hobby

4105 Fieldstone Road

Champaign, Illinois 61822

(877) 504-0233

www.horizonhobby.com

Warning

An RC aircraft is not a toy! If misused, it can cause serious bodily harm and damage to property. Fly only in

open areas, preferably at AMA (Academy of Model Aeronautics) approved flying sites, following all instructions

included with your radio and engine.

Servo Selection

The servos used for the control surfaces of the Edge 540 must have a minimum of 80 ounce inch of servo

torque. In the prototype edges, we used JR8411 servos. On the rudder we used ONE JR8611 servo. Two servos

are recommended if using other servos on the rudder.

Section 1 – Aileron Servo Installation

Required Parts

• Wing panel (right and left)

Required Tools and Adhesives

• Phillips screwdriver (small)

• Drill bit: 1/16"

• Drill

• 12" Servo Extension (JRPA098)

• 24" Servo Extension (JRPA102)

Step 1

Install the servo hardware (grommets and eyelets)

included with the servo.

Step 2

Plug a 12" and a 24" servo extension onto two of

the servos. Either tie the servo leads together, using

a commercially available connector, or use unwaxed

dental floss to secure the extensions to prevent them

from coming loose during flight.

Step 3

Tie a weight to a piece of string. A wheel collar works

great in this application. Lower the string into the

wing from the aileron servo opening. Let the weight

drop out through the wing root for the servo.

Section 1 – Aileron Servo Installation

Step 4

Insert the servo with the 24" extension towards the

tip of the wing. Use the string to pull the servo lead

through the wing. Position the servo so the output

shaft is towards the trailing edge of the wing. Use

a 1/16” drill bit to drill the locations for the servo

screws. Mount the servos using the hardware

provided with the servos.

Step 5

Repeat Steps 3 and 4 for the servo near the root of

the wing panel.

Step 6

Repeat Steps 1 through 5 for the remaining

wing panel.

Photo for Step 4

Section 2 – Aileron Control Horn Installation

Required Parts

• Wing panel (left and right)

• Aileron (left and right)

Required Tools and Adhesives

• Felt-tipped pen • Drill bit: 5/32"

• 8-32 tap • Tap handle

• Square • Ruler

• 30-minute epoxy • Rubbing alcohol

• Drill (drill press preferred)

• 8-32 x 2" Hangar 9®control horn screw (4)

(Included in HAN1220 (JR®) or HAN1221 (FUT))

• Hangar 9 control horn hex nut (4) (Included in

HAN1220 (JR) or HAN1221 (FUT))

Step 1

Tape the aileron to the wing. Make a mark 3/4"

away from the edge of the servo towards the tip

of the wing. Using a square held in alignment (90°)

with the mark and with the trailing edge, mark the

aileron with a pen where the straight edge intersects

the aileron hinge bevel.

Step 2

Measure exactly 3 1/2" forward from the trailing edge

of the aileron and make another mark using a felt-

tipped pen. The intersection of the line from Step 1

and this line will be the position for the control horn.

Step 3

Repeat Steps 1 and 2 for the second control

horn location.

Step 4

Remove the ailerons from the wing. Use rubbing

alcohol to remove any tape residue.

Step 5

Using a 5/32" drill bit and drill press, carefully drill

through the aileron at the marked position. Be

especially careful when penetrating through the top

surface of the aileron, as it’s easy to split out the

wood and rip the covering. Placing a wooden block

under the aileron and drilling slowly will prevent

these problems. If you choose to use the countersink

screws included in the Hangar 9® Hardware

Package, countersink the top of the aileron to allow

the screws to fit flush.

Section 2 – Aileron Control Horn Installation

Note: A hardwood block (hard point) is

located below the sheeting; you will be drilling

through this. Make sure to drill the hole

perpendicular to the top of the aileron.

It is highly recommended to use a drill press

to achieve this.

Step 6

Using an 8-32 tap, tap the hole just drilled

in the aileron.

Work Surface

Drill

Step 7

Mix a small amount of 30-minute epoxy and lightly

coat the inside of the tapped hole and the 8-32 x 2"

Hangar 9®control horn screw. From the top of the

aileron, screw the 8-32 x 2" into the tapped hole and

securely tighten. Wipe away any excess epoxy with

rubbing alcohol and a paper towel. Screw the hex nut

in place as shown. Allow the epoxy to fully cure.

Step 8

Screw the molded swivel link onto the 8-32 screw

until the distance from the aileron surface to the

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