Welcome to http://www.edge540.com 

A sub web site of http://www.rcflier.com

This web site is hosted by Bob Hudson.

The pages on this web site document MY procedure and assembly of my Carden Edge 540

I am by no means a professional or "master" builder and these procedures may not be the best methods for you.

Carden provides a nice construction guideline and color photos as an aid to building their kits.

I have chosen to build things in a little bit different order than they lay out in their manual

See 268 Laying out the hinge locations on the wing TE and aileron LE

See 269 tools and drills we will use

See 270 spot the hinge locations with your pointy pick

See 271 drill the locations with a 1/16" drill (so it won't wander)

See 272 open the holes up to 1/8".Drill about only half the depth of the hinge

See 273 The hinge points are 3/16" dia.
Slide a wheel collar on the drill and adjust it so you "just barely" drill through the thickness of the LE / TE

See 274 The wheel collar "depth gauge"

See 275 Use a 3/16" dia dowel to press into the hinge hole
Mark a line on the dowel for the depth of the hinge

See 276 We "press open the 1/8" hole we drilled earlier instead of drilling it to the same dia as the hinge. This prevents the foam beads from ripping out of the hole with a coarse drill

See 277 Push the dowel in to the "depth gauge" mark

See 278 Push a hinge into the center hinge hole (nice !)

See 279 Give it a "little" whack with a small hammer so the knuckle seats itself

Use this same hinge and do the same thing to the end holes

See 280 Install three hinges and check the fit (nice !!)

See 281 Push the aileron down into place. Nice fit

See 282 Bevel the ailerons

Notice the pen line on the surface of the LE and TE

See 283 Check the fit

See 284 Use your little hand plane

See 285 Rough off the bevels

See 286 Hmmm, what do we do in the corners !!

See 287 Rough up the corner as close as you can. Use a hand knife to get the rest in the corner

See 288 Finish sand the bevels to the pen lines

See 289 Re-install the hinges and check the fit

See 290 Lots of movement

See 291 Corner looks good

See 292 See the corner from the other side of the wing

At the root of the control surface (which is thicker than at the tip) the bevel line starts at the joint where the LE / TE meets the foam core.  At the tip the bevel line does not meet the joint. This is because the wing / control surface is thinner near the tip than it is at the root.

See 293 Right wing panel mounted to the fuse, the aileron is taped on for now

See 294 Left wing panel