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

How To

540wing.jpg (69460 bytes)

See 540 wing and aileron layout

wing.jpg (36935 bytes)

See 540 wing, same as above with dimensions

540skins.jpg (104529 bytes)

See 540 skins, How I laid out the 4" x 48" balsa sheets for the wing skins. Note the four 6" add extensions

servo.jpg (21950 bytes)

See JR 8411 servo dimensions

plate.jpg (49308 bytes)

See Servo simple view

linkage.jpg (24390 bytes)

See Servo, Rocket City links, JR titanium turnbuckle layout

rcable.jpg (110684 bytes)

See Rudder pull - pull cable and crimps (90 pound cable nylon covered)

tailwheel-109.JPG (36502 bytes) See Rudder to tailwheel connection with springs
hardware1.jpg (42537 bytes)

See Servo linkages and ball links hardware 

hardware2.jpg (169280 bytes)

See Rocket City #69D Control Surface Swivel Link, #87 Ball Link, Sullivan #549 4-40 Eye Bolts  

hardware3.jpg (35732 bytes)

See Servo linkages and ball links hardware , ( practice layouts )

hardware5.jpg (39807 bytes)

See Servo linkages and ball links hardware 

canopy-paint-024.JPG (35949 bytes)

See Canopy "speckle paint"

   
   
Servo Bay Fabrication and Servo Installation
servo-045.jpg (32687 bytes)

See The servo bay with the wooden servo rails glued in

servo-047.jpg (32475 bytes)

See The servo with a standard metal type output arm.
This one is from SWB MFG
 
Hangar 9 arms do an excellent job as well

servo-047.jpg (32475 bytes)

See the JR Output Shaft Support package. (Don't get too hyper, the price tag is Canadian dollars!!!)

servo-048.jpg (44670 bytes)

See a closer view of the package. Notice the bracket that installs over the servo mounting grommets. The bracket has the tall Ball Link support screwed onto it.

servo-049.jpg (37470 bytes)

See a view of the servo, output arm, ball links, H9 titanium turnbuckle, and Rocket City control hook ups

servo-050.jpg (38409 bytes)

See another view of the same

servo-051.jpg (29114 bytes)

See close up view

servo-052.jpg (35942 bytes)

See VERY close up view at the servo

servo-protractor-02.jpg (65608 bytes)

See Servo protractor-1

servo-protractor-03.jpg (68162 bytes)

See Servo protractor-2

aluminum-arm-DB-arm.jpg (31735 bytes)

See The Dubro Heavy Duty servo arm is not a good choice, how do you tighten the ball inside the servo arm pocket?

bevel.jpg (40507 bytes)

See How to figure out your beveling

The wing will be thicker at the root end (left side) than the root end (right side)

Determine the amount of angle you want and lay it out on the thick end (end view)

Layout the same angle on the thin end (end view)

Notice that the width at the top and bottom of the LE or TE is wider on the tip end than on the root end

(i.e.. the root end almost comes to a point but the tip end is wider from the edge of the bevel to where the LE or TE meets the foam core)

wing-hooks-1-800.jpg (37959 bytes) Airplane restraint hooks.
wing-hooks-5-800.jpg (32705 bytes)  

 

 Work Bench

I don't have plans, but I keep getting requests, so here's a little note on how I build my benches

Essentially it's 3/4" ply, 8 feet long and 30" wide ( or whatever you feel like making it.)

The ends ( uprights) are also 3/4" ply, cut to the height and width I want the bench, .

I cut the left over 18" length wise into 6" wide strips, and cut off 1-1/2" from the length. This permits them to slide under the bench between the end panels

These pieces are glued and screwd ( with 2" long screws) on the UNDERSIDE under the front edge, rear edge, and down the middle. 

These lengthwise pieces turn the bench into a bit of an "I beam" and make it very strong lengthwise.

 I put a pice of drywall on the table I use for building ( gluing etc) so I can stick pins in it. Easy to throw away and replace as needed.

 I have 3 of these benches in my workshop !!

 On the bench that I skin my wings and foam parts I use 2 pieces of 3/4" ply for the top. This provides a much sturdier surface.

 Since concrete floors are not always level I have leveled this table from end to end, side to side and also diagonally, so it is extremely level and warp free.

 I also have center supports made of 3/4" ply screwed onto the front and rear "under beam" that go down to the floor. I cut these perfecly to length after the table has been leveld and check for no bowing. these support more load on the table and prevent it from "wowing" in the middle.

 When I skin my big wings I put YET another piece of 3/4" ply on the top of the table, at one end  / corner,  as the "under pad" for my foam cores. This piece is cut slightly larger than the size of my 40% wing panels, about 2" bigger all around.

 I have a second piece that I put on top of the wing cores, on top of which I place my foot square cement patio stones. They weigh 20 pounds each and are easy to handle  This upper pad helps spread the load out evenly over the wing core. I leave the cores to cure ( I use Probond) for 24 hours.

  Movies

Movies

Drilling Robarts Hinge pin holes in your leading and trailing edges

Cutting the Servo Wire Channel in the top of the wing

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