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Nov 04, 2007, 12:22 PM
Precision Aerobatics Team
demonGti's Avatar
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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

CG is 76mm from the leading edge measured at the fuse.
Last edited by demonGti; Jul 24, 2012 at 02:52 AM. Reason: Added links to build PDF guide
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Nov 04, 2007, 12:36 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP

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.
Nov 04, 2007, 12:50 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP
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.
Last edited by demonGti; Nov 04, 2007 at 01:25 PM.
Nov 04, 2007, 01:07 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP
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.
Nov 04, 2007, 01:17 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP

All done!

The Egde is done, ready for a test flight, pilot, wheelpants and all.......
Nov 04, 2007, 01:38 PM
Time for another motto!
May I be the first to demand those plans! Quick, it's a matter of life or life!
Nov 04, 2007, 01:40 PM
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ededge2002's Avatar
nice job! what was the all up weight? good luck.....

one of mine(
Nov 04, 2007, 01:54 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP
My AUW came in at 809g after I added some bracing in the tail end of the fuse.
Nov 04, 2007, 05:11 PM
Precision Aerobatics Team
demonGti's Avatar
Thread OP


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.
Nov 04, 2007, 06:47 PM
Blue Collar DLG Marshall
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
Nov 04, 2007, 07:02 PM
Registered User
That's awesome, DemonGTI!

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

Nov 04, 2007, 10:19 PM
Registered User
shockflyer12345's Avatar
Nice job!
Nov 05, 2007, 01:38 AM
Just one more.......
Sim69's Avatar
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!
Nov 05, 2007, 05:13 PM
Registered User
golem's Avatar
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.


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