Stevens Aero Model EDGE 540 User manual
R1.0
Span 50” / Length 45” / Area 440 Sq.” / Weight 26-30oz
© 2005 Stevens AeroModel. Page 1 of 46
WARRANTY
Stevens AeroModel guarantees this kit to be free from defects in both material and workmanship
at the date of purchase. This warranty does not cover any component parts damaged by use or
modification. In no case shall Stevens AeroModel’s liability exceed the original cost of the
purchased kit. Further, Stevens AeroModel reserves the right to change or modify this warranty
without notice.
In that Stevens AeroModel has no control over the final assembly or material used for final
assembly, no liability shall be assumed nor accepted for any damage resulting from the use by
the user of the final user-assembled product. By the act of using the user–assembled product,
the user accepts all resulting liability.
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.
Special recognition of:
Scott Stoops for thoroughly abusing the model prior to production and providing timely feedback on flight performance
and model setup.
Craig Killer for your work on the “Killer” Edge 540 logo.
The RC Groups Community for being the greatest sounding board for vendor to customer communications.
© 2005 Stevens AeroModel. Page 2 of 46
REQUIRED TO COMPLETE KIT:
Kit Contents:
1. Rolled Computer Drawn Plan Sheets
2. Illustrated Instruction Manual
3. Laser Cut Balsa and Hardwood Parts Sheets (See Parts Inventory Sheet)
4. 1 - Clear Canopy
5. 1 - Cowl Assembly (two piece)
6. 1 - 19.5” Carbon Wing Spar
1. 2 - 20” Carbon Trailing Edge Flat Stock
8. Large Hardware Bag
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2 - GWS 2” Light Foam Wheels
2 - .045” x 11.5” Wire
1 - 1/32” x 11.5” Wire
2 - Pre-Formed Landing Gear Struts.
2 - 6” Paper Tube.
1 - 1/8” x 2” Hardwood Dowel
9. Small Hardware Bag
4 – 1/8” x 0.474” Aluminum Tube
2 – Neo Magnet 3/16” x 1/16”
2 – Nylon Washer / Shims
1 – Pre-Formed 3/32 diameter Elevator Joiner Wire
8 – Blind Nut 4-40
2 – Blind Nut 6-32
2 – Knurled Head Screw 6-32 x ½”
8 – Machine Screw 4-40 x 3/8”
12 - #0x3/16” Screws
1 - #30 Stranded Kevlar Tape 12”
4 – Du-Bro Micro II Horn
4 – Du-Bro Micro II E/Z Link
6 – Sig Easy Hinge
1 – Tail Wheel ½” #60
Recommended Finishing Items:
1. Dubro Mini E/Z Connectors DUB845*
2. 1-2 Roll(s) of Solarfilm So-Lite, Nelson Lite, or Ultracote Lite – Iron on Film Covering.
Suggested Radio Gear:
1. 4-5 Channel Transmitter (4ch using “Y” harness for ailerons)
2. 4 - Sub Micro Servos (Hitec HS-55 or equivalent)
3. 2 - 6” Servo Extension
4. 2 - 12” Servo Extension
5. 1 - Micro Receiver
Suggested Power Systems:
1. Hacker A30-16M / Phoenix 35 ESC / 11x5.5 APC Thin Electric / 11.1v 3S1P ThunderPower 2100 PL. (300w)
2. Apache A30M-18T / Phoenix 35 ESC / 12x6 APC Thin Electric / 11.1v 3S1P ThunderPower 2100 PL. (300w)
3. Hacker A30-28S / Phoenix 25 ESC / 10x5 APC Thin Electric / 11.1v 321P Apogee 2170 or 2480 (250w)*
4. Apache A30S-30T / Phoenix 25 ESC / 10x5 APC Thin Electric / 11.1v 3S1P Apogee 2170 or 2480 (250w)*
*Requires motor stand offs to achieve proper location of motor output shaft.
Other Items You Will Need:
1. Thin and Medium CA (super glue)
2. Five Minute Epoxy
3. Wax Paper or Plastic Wrap
4. Sharp Hobby Knife
5. Fine Grit Sand Paper
6. Rat-Tail File
7. Masking Tape
8. Balsa Wood Filler
© 2005 Stevens AeroModel. Page 3 of 46
GENERAL ASSEMBLY INSTRUCTIONS:
Thank you, for purchasing this Stevens AeroModel Edge 540. This kit provides the builder and pilot a refreshing change
of pace from heavy “ARF” style plywood box airframe construction and blends stick and tissue design methods of the past
with state of the art CAD technology and precision interlocking laser cut parts; the result is something you will find truly
exceptional to build and fly. Please keep in mind that this kit is intended for a novice-intermediate builder and
intermediate-advanced pilot. If you do not meet these criteria it is recommended to seek help from a more experienced
builder / pilot.
Best Regards,
Bill Stevens
Stevens AeroModel “Laser Engineered Kits”
4550 Beaumont Rd.
Colorado Springs, CO 80916
Assembly Tips
READ THE INSTRUCTIONS and the plan sheet prior to starting any work!
Tape plans to work table. Cover with clear painters drop clot, wax paper, or plastic wrap.
Join all joints with Thin CA unless otherwise specified.
DO NOT REMOVE THE PARTS FROM THE BALSA SHEETS UNTIL REQUIRED! In-fact while the balsa
parts are still retained in the sheets now is a good time to run a few good swipes with a sanding block over both
sides of the sheet to remove any resin/residue from the laser cutting process.
DO NOT FORCE THE FIT – when in doubt double check your parts – Many of the joints will be exceptionally
snug it is recommended that each part be worked into position slowly by rocking the part back and forth. I like
to use a rat-tail file to knock the edge off of the interlocking components to ease assembly. If you feel that you
have a poor connection check first to see that the part is not upside down. Reference each piece against the
plan sheet or photo.
Making solid glue joints: Hold parts together on top of plan sheet using moderate pressure to fit parts - wick thin
CA into joint. (There is no need to pin parts to work table as all pieces interlock and self - jig.)
Tired of gluing your fingers to your work? – try this: wrap masking tape around your thumb and index fingers
to prevent getting “stuck”.
© 2005 Stevens AeroModel. Page 9 of 46
Tail Feathers
1. Build the Rudder, Vertical Stabilizer, Elevator, and Horizontal Stabilizer. Parts are grouped according to tail
section component on the 1/8” balsa sheet. Work with each component separately. Assemble over plan sheet,
removing only those parts necessary to complete each individual component. Start each assembly by building
up the outside edges (just like a puzzle) – finish by inserting center truss parts. Though the parts fall together
and self jig, pay particular attention to orientation and making solid glue joints.
Wire Joiner 3
32" x 2.75"
Trim to length if required
and slightly adjust shape
so that elevator assembly
lays flat to your building
surface with no binding or
interference to horiz.
stabilizer.
1/32" Ply Doubles Top AND
Bottom of Elevator Assembly
- Align with drill holes for
control horn.
1/8" Aluminium tubing joiner
bushing - nests within elevator
assembly as illustrated.
2. Elevator Joining Wire. Verify that the provided 1/8” aluminum bushings are of the appropriate length and nest
within the elevator assembly as indicated on the plan sheet. Capture the bushing within the elevator using the
1/32” ply elevator doublers as indicated on the plan sheet. Be careful to avoid getting glue inside the bushing.
Allow adequate time to dry then test fit the elevator joining wire. This wire is pre-formed but you will be required
to do some minor adjusting (use heavy pliers) to the wire joiner until your joined elevator assembly lies perfectly
flat on your work surface and there are no interference issues with the horizontal stabilizer.
3. Sand all surfaces with fine grit sand paper, rounding leading edge pieces while leaving trailing edge parts
square, in preparation for your preferred hinging method (Centered CA Hinging is Recommended).
Fuselage
Fuselage components are exceptionally brittle until the entire assembly is complete – this is especially true aft of the wing
saddle. Handle parts accordingly and do not force the fit!
1. Assemble the major fuselage components; fuselage sides and formers F3, F4, F5, FB1, FB2, and FB10. Align
parts with rolled plan sheet and wick CA into joints.
Optional wing retention
using 316" Neo Magnet.
LEAVE OPEN
COOLING AIR
EXIT POINT
© 2005 Stevens AeroModel. Page 10 of 46
2. Assemble fuselage bottom plate. Tab 3/32 balsa part FB2 (assembled from FB2a/b) to FB1 (assembled from
FB1a/b/c) as illustrated below. To avoid warping the assembly set flat on your work table prior to gluing.
3. Add cross braces to the fuselage bottom plate starting forward and working aft. Begin with FB3 and FB4 which
forms the leading edge of the battery access. Next, install FB5, FB6, and FB7 which forms the trailing edge of
the battery access. Finish by installing FB8 and FB9. Reference photos below.
© 2005 Stevens AeroModel. Page 11 of 46
4. Assemble battery access hatch by aligning FB10 atop FB11. Once satisfied with alignment, wick thin CA glue
between parts. Photo below shows completed hatch.
5. Install magnetic battery cover catch. DON’T SCREW THIS UP – READ ON! Magnets are polarity sensitive.
Locate your two 3/16” x 1/16” rare earth magnets notice that the magnets are stuck together along one side of
each magnet – reversing one magnet will result in the magnets repelling each other. Since we are relying upon
the magnets to act as a catch mechanism for the hatch they must attract each other. Allow the magnets to stick
back together – use a permanent marker to mark the outside surface on either side of the stack. Now, separate
the magnet stack and install one magnet within FB7 making certain that the side you marked with permanent
marker is facing INSIDE the fuselage. The battery hatch cover (completed in the previous step) has two 3/16”
cut-outs to accept magnets. Test fit the cover to the fuselage and mark the side of the cover which corresponds
to the location of FB7. Now, install the second magnet, within the battery cover assembly, with the marked side
DOWN. The photos below reference the magnet install and completed fuselage bottom plate assembly.
© 2005 Stevens AeroModel. Page 12 of 46
6. Assemble the fuselage firewall. Locate the 1/8” lite ply firewall parts F1 and F1a. Take note of the locating
marks etched on part F1 this marked side will become the back side of the firewall. Locate part F1a atop F1
and wick thin CA glue between parts – wick glue in from both sides until you are satisfied that the part is
properly bonded. Finally, drive the four 4-40 blind nuts into position on the back side of F1 as illustrated below;
secure these blind nuts by wicking thin CA along the outside of the nut – do not allow glue to come in contact
with the internal threaded portion of the blind nuts!
7. Assemble the battery tray BT1 to the slots on the back side of the firewall as indicated below.
© 2005 Stevens AeroModel. Page 13 of 46
8. Locate the 3/32” balsa former F3 (assembled from F3a/b). Key F3 to the aft edge of the battery tray BT1, then
key the fuselage side to span the assembly as illustrated below. Repeat for the opposite fuselage side.
9. Double the aft servo pockets on the INSIDE of each fuselage side using the 1/32” plywood doublers SR3.
10. Add the wing spar carry through and locating dowel re-enforcements. Locate the 1/8” lite ply part BT2 (Early
kits have this marked as WS1) and key within the fuselage to the top of BT1. Next, locate the 1/32” ply part
BT3 and key within the fuselage to the top of BT2. Reference the plan sheet for specific location.
© 2005 Stevens AeroModel. Page 14 of 46
11. Assemble the spar carry through. Locate the 1/8” lite ply parts WS1a, WS1b, and WS1c. These are assembled
to form a box that spans the wing spar carry through cut-outs in the fuselage sides and interlocks with the
notches in BT1.
12. Install the 3/32” balsa former F2 and 1/8” balsa former F7 as illustrated below.
13. Key the fuselage bottom plate (assembled in steps 1-5) to the bottom of the fuselage assembly as illustrated
below.
© 2005 Stevens AeroModel. Page 15 of 46
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