AeroWorks 100cc Edge 540 ARF-QB Assembly Manual

Brand: AeroWorks

Model: 100cc Edge 540 ARF-QB

Category: Remote controlled toys

Type: Assembly Manual

100cc Edge 540 ARF-QB

(Quick Build)

ASSEMBLY MANUAL

AEROWORKS

4903 Nome St– Denver, CO. 80239

www.aero-works.net

TABLE OF CONTENTS

Page

Aeroworks Contact Information …………………………………………………………………………. 3

Introduction / Warranty…………………………………………………………………………. ………. 4

Kit Contents………………………………………………………………………………………………… 5

Items Needed To Complete ……………………………………………………………………………….. 8

Tightening and Re-shrinking The Covering ……………………………………………………………… 9

Ultracote™ Colors …………………………………………………………………………………………. 10

Checking Seams and Color Overlaps for Good Seal / Sealing Hinge Gaps ………..………………….. 11

Checking Hinges For Proper Throw………………………………………………………………………. 12

Wing Assembly………………………………………………………………….…………………………. 13

Stab and Elevator Assembly………………………………………………………………………………. 19

Rudder and Rudder Servos Installation ………………………………………………………. ……….. 22

Tail Wheel Installation ………………………………………………………………………….. ………. 31

Main Landing Gear and Wheel Pant Installation ….………………………….. ………………………. 34

Engine Installation ……………..…………………………………………………………………………. 38

Throttle and Choke Servo Installation …………………………………………………………………… 40

Ignition Installation . …………………………..…………………………………………………………. 45

Fuel Tank Assembly and Installation …………………….……………………………………. ………. 48

Standard Muffler/Cowl Installation ……………………..……..………………………………. ………. 55

Canister Muffler/Cowl Installation ……………………………………………………………. ………. 59

Radio Installation …………………………………………………………………………………………. 63

Preflight Preparation ………………………………………………………………………...….. …….. .. 66

Decal installation ………………………………………………………………………………………… 68

Center of Gravity– CG Buddy……………………………………………………………………………. 72

Center of Gravity / Control Throws ……………………………………………………………. ……… 74

Control Deflection Table ………………………….………………………………………………………. 77

Preflight Check List ……………………………………………………………………………………… 78

4903 Nome Street

Denver, CO 80239

Phone: (303) 371-4222

Fax: (303) 371-4320

Website: www.aero-works.net

E-mail: [email protected]

Thank you for choosing the Aeroworks 100cc Edge 540 ARF-QB. We put great effort

into making this plane the best model you will ever build and fly. We have provided you

with the highest quality kit and performance possible. We wish you great success in the

assembly and flying of your new Aeroworks 100cc Edge 540 ARF-QB.

!WARNING!

An R/C aircraft is not a toy! If misused, it can cause serious bodily harm and property

damage. Fly only in open areas, and AMA (Academy of Model Aeronautics) approved

flying sites. Follow all instructions included with your plane, radio, and engine.

Aeroworks manufacturing guarantees this kit to be free from defects in both material

and workmanship at the date of purchase. This limited warranty does not cover any

component parts damaged by use or modification. In no case shall Aeroworks liability

exceed the original cost of the purchased kit. Further, Aeroworks reserves the right to

change or modify this limited warranty without notice.

In that Aeroworks has no control over the final assembly or materials used for final as-

sembly, 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.

We, as the kit manufacturer, have provided you with a top quality, thoroughly tested kit

and instructions, but ultimately the quality and fly ability of your finished model

depends on how you build it; therefore, we cannot in any way guarantee the

performance of your completed model, and no representations are expressed or

implied as to the performance or safety of your completed model.

INTRODUCTION

Your new 100cc Edge 540

ARF-QB is a highly aerobatic airplane. It is capable of both pre-

cision and 3-D maneuvers. The aircraft builds easily, quickly, and precisely due to its state

of the art CAD design, LASER cut technology, and high quality included hardware. We

hope you enjoy building and flying your 100cc Edge 540 ARF-QB.

Great care has been taken in both the design and manufacturing of the 100cc Edge 540 ARF

QB to allow for the strongest and lightest construction possible. Only the highest quality ma-

terials from the covering, paint, wood and hardware have been used in the construction of

this model.

The 100cc Edge 540 ARF-QB has been individually hand built, covered and painted by

trained and experienced craftsmen with over 25 years of manufacturing experience. Using

CAD design, laser cut technology and jig-built assures accuracy in all stages of production.

The 100cc Edge 540 ARF-QB is designed for gas engines in the 100cc category. The DA-

100cc engine is shown in the assembly instructions. The aircraft was tested with the DA-

100cc and has outstanding performance. The final choice of engine is left up to the builder.

A computer radio is recommended to allow the pilot to take advantage of the full capabilities

of this aerobatic aircraft.

IMPORTANT Please read through this assembly manual carefully, before starting the as-

sembly of your new model. Inventory and inspect all parts and hardware for any imperfec-

tions or damage. Notify Aeroworks immediately if there are missing or damaged parts

and do not proceed with the assembly. Inspect all parts and hardware prior to any assembly,

failure to do so could void any warranty coverage.

INTENDED USE

This plane should not be regarded as a toy. This is an aerobatic plane and is recommended for pilots

who are beyond the trainer-stage and are comfortable with flying an aerobatic sport plane.

READ! LIMITED WARRANTY READ!

It is important to notify Aeroworks of any damage or problems with the model within 30

days of receiving your airplane to be covered under warranty. If you wish to return this air-

craft for any reason a 15% restock fee will be charged to the customer. In addition the cus-

tomer is responsible for all return shipping cost and all prior shipping cost will not be re-

funded. Parts will be fixed or replaced once the original item is returned at the owner’s ex-

pense. If you have any problems or questions, please contact Aeroworks.

Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the

construction or use of this aircraft, and therefore, will not be accountable for any property

damage, bodily injury or death caused by this aircraft.

Aeroworks cannot insure the skill of the modeler and cannot influence the builder during the

construction or use of this aircraft, and therefore,

The purchaser/operator accepts all responsibility of any and all structural or

mechanical failures.

KIT CONTENTS

100cc Edge 540 ARF-QB

BASIC AIRCRAFT PARTS:

Fuselage with pre-installed vertical fin – covered, fire-

wall fuel-proofed, pre-drilled three holes for the tail

wheel assembly::

(4) 8-32 blind nuts installed for main landing gear

(6) 4-40 blind nuts installed for the mounting of

the stab(4),Cowling(2)

(1) Engine box top hatch cover with AW logo in

stalled by (4) T2.6x8mm PWA screws

(1) Engine box bottom hatch cover with AW logo

installed by (4) T2.6x8mm PWA screws

(1) Bottom Canister Hatch installed by (4)4-40

blind nuts, (4)4-40x10mm hex style bolts and (4)

3mm flat washers

(1)Hatch cover for the landing gear installed by

(2) T2.6x14mm PWA screws

Canopy base—painted, with (4) 4-40 blind nuts

installed

(1) Tinted Canopy—glued on the canopy base

and painted, installed on the fuselage by (4) 4-

40x16mm hex style bolts

(4) #6 bonded washers for the mounting of the

canopy

(4) 3mm split lock washers for the mounting of

the canopy

3.5(o.d.) x1000mm Antenna tube installed

(2) 3.5(o.d.) x100mm pull-pull exit tube installed

(2) Elevator servo string installed

Left Wing with Aileron – covered: Pre-drilled for the

mounting of the control horns

8-32 blind nuts installed for the wing mounting.

(2) located pins installed pre-drilled hole for cot-

ter pin

(8) pin point hinges glued

(2) Aileron servo string installed

Right Wing with Aileron – covered: Pre-drilled for the

mounting of the control horns

(2) 8-32 blind nuts installed for the wing mount-

ing.

(2) located pins glued pre-drilled hole for cotter

(8) pin point hinges installed

(2) Aileron servo string installed

Horizontal Stabilizer with elevator assembly with (12)

pin point hinges (glued)---covered

Elevators Pre-drilled for the mounting of the con-

trol horns

Rudder with (7) pin point hinges (not glued) – covered

Rudder Pre-drilled for the mounting of the con-

trol horns

SUB ASSEMBLIES:

#1:

(1) Fiberglass Cowling w/ inside ring glued—painted

with (2) screws holes at bottom and (2) 6-32 blind

nuts installed

(2) 4-40x16mm hex style bolts for mounting cowling

(2) #6 bonded washers for mounting cowling

(2) 3mm split lock washers for mounting cowling.

(2)6-32x16mm hex head bolts for mounting cowling

(2) #6 bonded washers for mounting cowling

#2:

(1) 5mm 7075Aluminum Main Landing Gear --

painted

(2) 5x48mm AL Axle Bolts

(2) M8 lock nuts

(4) 5mm i.d. Wheel Collars with set-screws

(2) 100mm Dia. Main Wheels (Lite Type)

(4) 4-40x14mm hex style bolts for mounting wheel

pants

(4) 3mm flat washer for mounting wheel pants

(4) 3mm split ring lock washer for mounting wheel

pants

(4) 8-32x20mm hex head bolts for mounting main

landing gear

(4) 4mm flat washers for mounting main landing

gear

(4) 4mm split ring lock washers for mounting main

landing gear.

#3:

(2)Wheel Pants—1 Left and 1 Right---Painted

(4) 4-40 blind nuts installed on the wheel pants, 2 per

side.

#4:

(1) AL Tail Wheel Assembly with Rubber wheel –

LARGE

#5:

(1) 40mm o.d. Aluminum Tube for wing joint—

Anodized Black

(2) 12.5mm o.d. Aluminum Tube for stab joint – one

front and one rear, Anodized Black

(4) 8-32x25mm Hex head bots for wing mounting

(4) #8 bonded washer for wing mounting

(4) 4mm split ring lock washers for wing mounting

(4) 4-40x16mm Hex style head bolts for stab mount-

ing

(4) #6 bonded washer for stab mounting

(4) 3mm split ring lock washers for stab mounting

(4) 1.8mm cotter pins

#6:

(4) 4-40 3” Left hand and Right hand threaded push

rods with nuts and carbon tubes for ailerons

(2) 4-40 2-1/2” Left hand and Right hand threaded

pushrods with nuts and carbon tubes for elevators

(1) Wrench for the left hand and right hand

threaded pushrod

(2) 4-40x300mm Threaded pushrods

(2) 4-40 solder coupler with nuts

(2) 4-40 Metal clevises

(10) brass spacers – 4 for ailerons; 2 for elevators; 2

for throttle; 2 for choke

(16) 4-40 Ball Link – 8 for ailerons; 4 for elevators; 2

for throttle; 2 for choke

(16) 4-40x16mm hex style bolts

(16) 4-40 lock nuts

(16) Φ3mm flat washers

#7:

(2) 1x1300mm plastic coated pull-pull steel cable.

(4) 4-40 Metal R/C links with nuts

(4) 3.5x5mm brass pull-pull swaging tubes

(8) AL double control horns

(36) T2.6x16mm Phillips head mounting screws

(12) T2.6x12mm Phillips head mounting screws

(2) 4-40x36mm left hand and right hand threaded

pushrod for connecting rudder servo

(4) 4-40 Ball Links for connecting rudder servo

(4) 4-40x16mm hex head bolts for connecting rudder

servo

(4) 4-40x20mm hex head bolts for connecting rudder

servo

(4) Brass Spacers for connecting rudder servo

(4) 3mm flat washers for connecting rudder servo

(4) 4-40 Ball Links – Rudder

(4) 4-40 x16mm hex style bolts

(6) 4-40 lock nuts

(2) Brass Spacers for rudder

(2)Φ3 flat washers

#8:

(1) 1000cc Gas Fuel Tank Assembly

(1) 750cc Gas Fuel Tank Assembly

(1) 4ft. large gas fuel line

(4) Brass Barbs for fuel line

(2) Fuel filler Dot – 1 male and 1 female

#9:

(2)Throttle and Choke servo mounting trays

(1) Canister mounting bracket with Silicon Tubes

(3) Engine Mounting Template (DA100;3W100 and

Universal)

(2) 8x8x300mm Sponge for the receiver and battery

(1) 6x70x160mm Foam for the Fuel Tank

(1)6x100x160mm Foam for the Fuel Tank

(8) 8x450mm Nylon Ties for the fuel tank mounting

(10) 3x150mm Small Nylon Ties for the fuel line

(6) 356x12.5mm Velcro

(1) Card Stock (8”x11”) for making the template for

cutting of cowling

(1) pre cut template for cutting the bottom of the cowl

(1) Paper Degree Meter for the Rudder

(1) Φ12mm Aluminum Insert

(6) Rubber Grommets – each forΦ6mm,

Φ8mmΦ10mm – Fuel line and wire guide

#10:

(24) 6.35mm Aluminum Engine Stand offs.

#11:

(1) C.G. Buddy

#12:

(1) 300x300mm White Covering

(1) 300x300mm Cub Yellow Covering

(1) 300x300mm Pearl Charcoal Covering

(1) 300x300mm White Covering

(1) 300x300mm Orange Covering

(1) 300x300mm Pearl Charcoal Covering

(2) 20x1800mm transparent covering

#13:

(1) Custom throw meter

#14:

(1) Manual CD

#15:

(1) Vinyl Decal Set

Hardware:

ITEMS NEEDED TO COMPLETE

• 100cc gas engine with ignition, mufflers or

headers, with canisters or pipes, and all engine

mounting bolts, lock nuts, and washers.

• 4” Spinner and propeller of your choice

• 4 x aileron servos (min. 180 in./oz. Digital,

Metal Gear)

• 2 x rudder servos (min. 180 in./oz each or 300

in./oz. total torque, Digital, Metal Gear)

• 2 x elevator servos (min. 180 in./oz. Digital,

Metal Gear)

• 1 x throttle servo (fast / reliable)

• 1 x choke servo (fast / reliable) (Optional)

• Servo extensions - Heavy Duty - (22 gauge min)

3 x 11” Y harness, 2 x 6,” 2 x 12”, 2 x 24”, 2 x

48”

• 1 Receiver (PCM recommended)

• 1 x Receiver battery (min 6.0 volt / 1700ma)

• 1 x Ignition battery (min 4.8 volt / 1700ma)

• 2 switches with charge jacks (22 Gauge min)

Tools:

• Allen wrenches US and Metric.

• Dremel cutting disc and sanding drum tool

• Electric drill and selection of bits

• Flat head screwdriver

• Hobby heat gun

•

Hobby iron with protective sock

•

Masking tape

• Modeling knife

• Needle nose pliers or crimping tool

• Paper towels

•

Pen, pencil or felt tipped marker

•

Phillips screwdriver

• Ruler and tape measure

• Scissors

• T pins

• Waxed paper

• Wire Cutters

Adhesives:

•

15-30 Minute epoxy

•

Blue Loctite (Thread Locker)

• Epoxy mixing cups, sticks, brushes

•

CA kicker (optional)

• Thick and Thin CA

• Rubbing alcohol

• Wipes

!WARRING!

Some rubbing alcohols

may attack painted parts.

1. Open your kit slowly and take care not to dam-

age any parts of the kit. Remove all parts from

their plastic protective covers for inspection.

Before doing any assembly or installation of any

decals it is very important

to re-shrink or re-

tighten the already applied covering. Due to the

shipping process, heat and humidity changes

from different climates, the covering may be-

come lose and wrinkle in the sun. If you take the

time to re-tighten the covering, you will be re-

warded with a long lasting beautifully covered

model.

TIGHTENING AND RE-SHRINKING THE COVERING

2. Using your covering iron with a soft sock, gently

apply pressure and rub in the covering. If any

bubbles occur, your iron may be to hot. Reduce

heat and work slowly.

!IMPORTANT!

Go over any and all seams and color overlaps

with your iron to assure good adhesion of the

covering to the wood. This is especially im-

portant at the leading edges of the wings and

stabs.

3. If bubbles persist, use a small pin to punch holes

in the bubble to relieve trapped air and reheat.

4. Use your heat gun with extreme caution. Take

care not to apply too much heat to one area for

long periods of time. This may cause the trim

colors to over shrink and pull away leaving un-

sightly gaps on the color lines. The trim stripes

are especially vulnerable to over heating and

over shrinking.

Tightening and re-shrinking the covering is now

complete

. However, this is a never ending

process and should be checked after each

flying session.

1. Your model is covered with Ultracote™ cover-

ing. In case of repairs, the colors are:

Yellow/Charcoal/White Scheme

Cub Yellow #884

Pearl Charcoal #846

White #870

Ultracote™ Colors

Orange/Charcoal/White Scheme

Orange #877

Pearl Charcoal #846

White #870

1. Go over all seams and color overlaps with your

sealing iron.

Note: Even if your models covering has no wrin-

kles out of the box it is still very important to

go over all seams and overlaps to make certain

they are sealed securely. This is especially

important at the leading edges of the wings and

stabs. We recommend checking the covering

after each flying session.

CHECKING SEAMS AND COLOR OVERLAPS FOR GOOD SEAL

SEALING HINGE GAPS

2. Use covering iron to ensure all edges, seams,

and color overlaps are securely sealed.

3. Sealing hinge gaps. This is an optional step

but is recommended.

Cut strips of the supplied clear covering to fit

the hinge gaps. Use covering iron to seal the

clear covering snugly into the bottom of the

hinge lines as shown for air tight hinge seals.

Note: The clear covering does have a transparent

protective backing. This must be removed

prior to applying heat and to the surface.

IMPORTANT:

It is the responsibility of the purchaser /

operator to check the covering seams and

overlaps for security and a good seal.

Aeroworks is not responsible for failure of

covering seams or overlaps during flight.

Note: If covering continues to lift apply a small

amount of thin CA underneath the covering.

Then using a clean rag apply pressure to secure.

One of the most important tools in your

flight box is a roll of clear tape. This can be

used at the field for fast and easy repairs of

the covering. Then once you have finished

flying the covering can be permanently

repaired.

CHECKING HINGES FOR PROPER THROW

2. Evenly heat each hinge along the entire length of

the wing. This will allow the hinge glue to soften

and the hinge to move into it proper position.

Hold the surface at full deflection until the

hinges have cooled down and the glue has re-

hardened.

1. If the elevator hinges are tight follow the

same process as described for the wings.

Note: Once these steps have been completed

the hinges will throw to their full deflect-

tion.

IMPORTANT

1. If control surfaces will not throw to full deflec-

tion it may be necessary using a heat gun to

apply heat to the knuckle of each hinge. This

will allow the hinges to move freely.

Aileron Servo Installation

1. The ailerons have been pre-hinged and glued to

the wing panels and are ready for flight. No

other steps are necessary for hinging. Clear

Covering is supplied for sealing the hinge gaps if

desired. However, due to the precisely aligned

and minimal hinge gap this step is optional.

Gather the following items for each wing

panel:

• (2) Aileron Servos 172 in./oz torque ea re-

quired

• (1) 11” Y harnesses: Optional See below

• (1) 24” servo extension

As shown below to begin the servo installa-

tion.

Note: A 6” extension will also be needed per wing

when connecting aileron servos to receiver.

Note: If using a 12+ channel radio, match boxes, or

power expander with mixing capabilities it

will not be necessary to use a Y harness.

WING ASSEMBLY

2. Layout the servos, extensions and Y harness on

the wing to test fit the installation and ensure

servo leads are the correct length.

Minimum recommended servo:

172 in. oz. / Metal Geared / Digital

3. Attach the 6” extension to the servo lead and

secure with Aeroworks Safety Clip. Ensure the

connectors will not come apart from vibration or

light tension.

Safety Clips

Available

from

Aeroworks

5. Pull the servo lead through the root end of the

wing.

6. Attach the Y harness to the inboard servo lead

and secure with an Aeroworks safety clip. En-

sure the connectors will not come apart from

vibration or light tension.

Note: If using a 12+ channel radio, match boxes, or

power expander with mixing capabilities it will

not be necessary to use a Y harness.

7. Remove the balsa stick with the pull string from

the servo well and tie the pull string to the servo

lead as shown.

4. Remove the balsa stick with the pull string from

the servo well and tie the pull string to the servo

lead as shown.

9. Plug the male ends of the 24”extension into

the female ends of the Y harness. Next plug

the male end of this Y harness into the female

end of the other Y harness.

Builders Tip

10. Taping servo lead to the inside of the wing panel

will help to prevent lead from dropping back

inside of wing panel during transportation.

11. Install servo in servo well with the output shaft

toward the leading edge of the wing. Use a

1/16 bit to drill servo mounting holes.

8. Pull Y harness through root end of wing.

13. Repeat mounting steps for other servo so that

aileron servos are mounted in bottom of wing

as shown.

Note: Servo output shaft should face towards the

wing leading edge. Servo arms should point

towards the wing tip.

12. Install servo with servo mounting screws.

2. Assemble two pushrod and control horn

assemblies as shown. The ball link goes

between the left and right sides of the control horn

sides and is secured with a nylon lock nut.

IMPORTANT: The ball link for the root end

control horn goes in the bottom hole of the horn.

The ball link for the tip end

horn goes in the mid-

dle hole of the horn. This gives the correct offset

to eliminate binding and twisting of the aileron.

Note: It will still be necessary to either program or

use a after market type Match Box system to as-

sure your servos will not bind or fight against

each other.

Improperly installed servo linkages can cause ser-

vos to strip and ailerons to flutter. Aileron flutter

can and will destroy your model instantly!

Tip end

Middle hole

Root end

Bottom hole

Aileron Control Linkage Installation

1. Gather the aileron control linkage parts as shown

below. There are (2) 4-40 pushrods, (4) 4-40 ball

link assemblies, (2) Flat washers (2) brass spacers,

(2) left and (2) right side control horns, (1) Adjust-

ment wrench (4) carbon reinforcement sleeves and

(12) wood screws for each wing panel.

4. Align the control horns over the factory drilled

holes.

Note: Control horns have been set at a slight

offset to allow for maximum torque at full

deflection

6. Align the left and right sides of the control horns

to the mounting holes and secure using six wood

screws as shown.

5. Use thick CA on each screw prior to

installing to lock screws in place

Note: CA glues have a fast drying time.

Remember to work quickly

3. Correct installation of ball link, flat washer and

brass spacer to servo arm shown below.

Note: Flat washer prevents ball link from

coming off brass ball.

8. Plug the servos into the receiver and turn on.

Ensure servos are centered and the servo arms

are parallel to the aileron hinge line. Adjust

the length of the pushrods so that the aileron is

at the neutral position when the servo arms are

parallel to the aileron hinge line. Ensure all

servos do not fight each other at center or

either end point at full deflection. Take advan-

tage of servo programmers and match boxes

available today to achieve best results. This

will help keep servos from binding and

causing possible aileron flutter.

7. Install servo arm to pushrod as shown below.

9. Finished wing panel shown below, repeat steps

for remaining wing panel.

Elevator Servo Installation

1. The elevators have been pre-hinged and glued to

the stabs and are ready for flight. No other steps

are necessary for hinging. Clear covering has

been provided for sealing of the hinge gaps if

desired.

Gather the stab and elevator, one elevator

servo, and one 48” servo extension.

Note: 48” servo extension will be used to

connect servos to receiver during a later

step.

STAB AND ELEVATOR ASSEMBLY

2. Install servo in servo well with the output shaft

toward the leading edge of the stab. Fish the

servo lead through the stab and out of the stab

root rib.

3. Mark locations of servo mounting holes. Use a

1/16 bit to drill servo mounting holes.

4. Install servo with servo mounting screws.

1. Gather the elevator control linkage parts as

shown below. There are (1) 4-40 pushrods, (2)

4-40 ball link assemblies, (1) Flat washers (1)

brass spacer, (1) left and (1) right side control

horns, (1) Adjustment wrench (2) carbon rein-

forcement sleeves and (6) wood screws for each

elevator half.

Elevator Control Linkage Installation

4. Align the control horns over the factory drilled

holes.

Note: Control horns have been set at a slight

offset to allow for maximum torque at full

deflection

5. Use thick CA on each screw prior to installing

to lock screws in place

Note: CA glues have a fast drying time.

Remember to work quickly.

2. Assemble the pushrod and control horn assem-

bly as shown. The ball link goes between the

left and right sides of the control horn sides and

is secured with a nylon lock nut.

3. Correct installation of ball link, flat washer and

brass spacer to servo arm shown below.

Note: Flat washer prevents ball link from

coming off brass ball.

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AeroWorks 100cc Edge 540 ARF-QB Assembly Manual

Brand: AeroWorks

Model: 100cc Edge 540 ARF-QB

Category: Remote controlled toys

Type: Assembly Manual

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AeroWorks 100cc Edge 540 ARF-QB Assembly Manual

AeroWorks 100cc Edge 540 ARF-QB Assembly Manual

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