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.

“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.

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.

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.

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.

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.

 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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