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.

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.

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)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.

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.

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.

T-pin.

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.

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.

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.

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.

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.

This manual suits for next models

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