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Old Nov 04, 2007, 11:22 AM
Precision Aerobatics Team
demonGti's Avatar
South Africa, GP, Randburg
Joined Dec 2006
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Build Log
Big 46" EDGE 540 (The next step after BFU)

Hi All

Those of you who built my BFU , or followed the thread, will appreciate the next level... a full-fuse Edge 540 with profiled wings and flight characteristics not unlike a balsa kit.

Constructed mainly from the same 10mm Polystyrene panels (similar to packaging foam) and a dowel to brace the wing. After having loads of fun with the BFU, I decided to build something with better gliding ability but still cheap and light. So hear it is.... with a wingspan of about 46" (1175mm) and 500 square inches of wing area. My proposed AUW is 800g including 2200 3S lipo and a 100g 1000kv outrunner.

I started the project by scaling the official dimensions from the FAI for their scale aerobatic F3M Edge 540 to suit a plane of 800g, then tweaked it for my own needs.

Direct links to Build guide PDF's:
Part 1
Part 2
Part 3
Part 4
Part 5
Addendum

CG is 76mm from the leading edge measured at the fuse.
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Last edited by demonGti; Jul 24, 2012 at 02:52 AM. Reason: Added links to build PDF guide
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Old Nov 04, 2007, 11:36 AM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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Cut and glue

I cut out the panels for the fuselage and tail feathers from 10mm polystyrene sheet and started glueing. I used 40mm thick firm polystyrene to shape the nose, I sanded the shape in with some 400 grit sandpaper on a sanding block.
The base for the LG was also made from thicker 40mm firm polystyrene.
To get the shape of the tail end of the fuse I had to cut some grooves out of the panel about 2 thirds deep to allow the foam to bend without breaking.
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Old Nov 04, 2007, 11:50 AM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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My rudder and elevator were hinged with thin pieces of polycarbonate (works great and friggin' strong). The turtle deck is made from a 20mm thick panel which I tapered slightly toward to nose (sorry no pics of this process). A piece of thin ply was glued to the LG base from the bottom. The LG is a piece of ally which I bent into shape and screwed onto the ply. I covered the base of the LG with foam to conceal the screws (looks nice but I may regret this later)

I had to put some colour on this thing to see if it was gonna look the way I planned.
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Last edited by demonGti; Nov 04, 2007 at 12:25 PM.
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Old Nov 04, 2007, 12:07 PM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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I will post a detailed PDF of the build process later once I have compiled it, but for now the Edge has grown wings. Here it is nearly complete, just canopy and electronics are missing. The motor is installed though, I glued a piece of thin ply to the inside of the nose with holes pre-drilled. The outrunner screws onto the ply from the inside using the ally cross mount that comes with most outrunners. Don't worry, the nose was carefully cut pre-assembly to achieve the correct thrust angle when the ply is glued in place, give or take a thin washer or two.
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Old Nov 04, 2007, 12:13 PM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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Servos are in... ESC installed and nearly ready to go!
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Old Nov 04, 2007, 12:17 PM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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All done!

The Egde is done, ready for a test flight, pilot, wheelpants and all.......
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Old Nov 04, 2007, 12:38 PM
Time for another motto!
Utrecht, The Netherlands
Joined Jul 2006
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May I be the first to demand those plans! Quick, it's a matter of life or life!
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Old Nov 04, 2007, 12:40 PM
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Newmarket,Ontario, Canada
Joined Dec 2002
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nice job! what was the all up weight? good luck.....

ededge2002
one of mine(http://www.rcgroups.com/forums/showthread.php?t=757160)
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Old Nov 04, 2007, 12:54 PM
Precision Aerobatics Team
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South Africa, GP, Randburg
Joined Dec 2006
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My AUW came in at 809g after I added some bracing in the tail end of the fuse.
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Old Nov 04, 2007, 04:11 PM
Precision Aerobatics Team
demonGti's Avatar
South Africa, GP, Randburg
Joined Dec 2006
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Dxf

Here is a DXF of the panels you need to cut out. It is not a pretty file, it is from my workings..... a nice clear scale PDF is in the pipeline. I just thought I'd post this in case anyone wants to get ahead start on cutting out the bits.

PS. you will need four of the same panels for the wings.
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Old Nov 04, 2007, 05:47 PM
Blue Collar DLG Marshall
Greensboro, NC
Joined Jun 2007
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OH BUDDDY, Man do I need some plans for this baby. I was going to upscale a Nano Shark for a buddy of mine but this is a much better choice. Please post some plans asap. I can figure most of it out from your excellent build thread but I need patterns to use to cut my parts.

Thanks, PP
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Old Nov 04, 2007, 06:02 PM
Registered User
LI, NY
Joined May 2006
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That's awesome, DemonGTI!

I'm looking forward to PDFs so, I can get building!

Thanks,
Adam
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Old Nov 04, 2007, 09:19 PM
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United States, MD
Joined Nov 2004
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Nice job!
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Old Nov 05, 2007, 12:38 AM
Just one more.......
Sim69's Avatar
Brisbane, Australia
Joined Nov 2005
216 Posts
This thing is going to be a HUGE hit! I've been searching the web for full fuse plans for an edge 540 ever since Tim H hinted at a full fuse version of his profile edge. Bring on the PDF!!!



I've subscribed to this thread!
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Old Nov 05, 2007, 04:13 PM
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golem's Avatar
Maryland, USA
Joined Mar 2006
896 Posts
Looks like another winner! Has all the qualities - Looks, Ease of Build, and Value.

My loss I know, I never got around to the BFU this past summer. Guess I now have two of yours on my list.

Cheers,
golem
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