Edge 540

Edge 540 (60-90)
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Aircraft

This ARF is made by Seagull Models. It's my first "60 to 90 size" airplane. Maiden flight was in August 2006. More pictures of this aircraft are here.

Quick Specs:
Wingspan:	68.2 inches (5 ft. - 8 in.)
Wing Area:	753 sq. inches
Length:	60.6 inches
Engine:	Saito FA-125a - 4 stroke
Servos:	Futaba (4) 3010, 3305, 3004
Battery:	Futaba 4.8v 1500mAh NiCd
Radio:	Futaba 6EXA-S and R127DF
Weight:	8.5 lbs.
Construct:	Balsa, Lite-ply, UltraCote
Prop:	15x6 MAS (Nylon)
Total Cost:	$ 918.00 (w/ radio, engine)

Edge 540 with Saito 125 - Seagull Models

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5-21-2006	Acquired Edge 540. Still need to make final decision on engine, servos, and receiver battery.
5-30-2006	Ordered Saito FA-125a engine, Futaba servos, and extension wires.
6-7-2006	Started building Edge 540. Installing CA hinges for ailerons, elevator, and rudder control surfaces.
6-10-2006	Installing aileron servos and linkages.
6-16-2006	Installing engine and cowl (cutting and fitting).
6-23-2006	Started on tail (epoxy stabilizers, servos and linkages, etc.).
7-3-2006	Throttle servo installed.
8-15-2006	Working on final to-do items.
8-21-2006	Completely finished and ready to break-in motor and then maiden.
8-22-2006	Installed GP 2-3/4" aluminum spinner and Saito 8mm adapter kit.
8-23-2006	Ran engine at field to break-in.
8-24-2006	Good maiden flight (see Flight Log below).

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Additional Components and Supplies

Engine: Saito FA-125a 4-stoke (1.25 cu. in. - 20.52 cc - 2.2 HP at 9000 rpm max.)
Glow-Plug: O.S. F (Medium)
Servos: (4) Futaba s3010 ailerons and elevator, s3305 for rudder, s3004 for throttle
Servo Accessory: Futaba SR10 Dual Servo Reverser (for dual elevator servos)
Servo Extensions: 24" Pro HD extension (HCAM2721), 6" Y-adapter (FUTM4130), (2) 9" extensions (FUTM3910)
Servo Misc: Dubro servo arms Futaba J (8) (Cat. No. 673)
Receiver Battery: Futaba NR4F 4.8v 1500mAh NiCd (FUTM1285)
Propeller: 15x6 Master Air Screw (MAS) Fiberglass-filled Nylon
Great Planes switch/change mounting assembly
Dubro medium silicone fuel tubing / red and clear (Cat. No. 892)
Dubro Fill-It Fuel Dot (Cat. No. 840)
Sullivan Head Lock Remote Glow Plug Connector (No. M-021)
(2) No. 2 x 1/2" Socket Head Sheet Metal Screws (# 381)

Replaced (Substituted) Hardware

(1) Great Planes 2-3/4" aluminum spinner
(1) Tru-Turn TT-0823-A 8x1.25mm Double Jam Nut Kit (Saito 1.25 spinner adapter)
(1) Dubro 10-32 x 1" Hex Socket Head Cap Screw (properly sized spinner screw)
(2) Dubro 3" rubber wheels
(2) Dubro spring steel axle shafts sets 1-1/4" x 5/32" (Cat. No. 247)
(4) Dubro Dura-Collars 5/32"
(4) Dubro 8-32 x 1-1/4" hex head cap screws & metal nuts with nylon insert
(4) Dubro M4 metal nuts with nylon insert (aircraft)
(8) Dubro 4-40 brass threaded inserts (Cat. No. 391)
(8) Dubro 4-40 x 1/2" hex head cap screws
(1) Dubro Kwik-Grip E/Z Connector [Throttle] (Cat. No. 608)
(1) Sullivan Tail Wheel Bracket 40-60 5-12 lbs. 5/64" axle (No. S860)
(1) GP 1" Rubber/Aluminum Tailwheel for 3/32 axle (GPMQ4241)
(2) Dubro Dura-Collars 3/32" (#138)

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Construction Details

I basically just followed the manual, so I'm only going into detail on items that were additional or contrary to it.

If your kit is like mine, the aileron mounting plates/ covers might be factory installed incorrectly. The servo arm slots go towards the wing's leading edge. Then, I oriented the slots towards wing tip (as the manual shows), but others have oriented them towards the wing root (as Horizon recommends). Whichever way you chose, be sure the control horn is securely mounted in solid wood, forward of the solid reinforced area of the aileron and the rods end up being perpendicular to the aileron. I opted to use Dubro (Futaba J cat. no. 673) servo arms that had 5 holes to reach far enough above plate (and allow full movement without binding).

Center servos with radio (zero trim) before attaching arms (closest to perpendicular). Secure servo extension wire connection with dental-floss or heat-shrink tubing. Slots must be enlarged at ends to allow full range of motion without binding. Wick some thin CA into 4 plate screw holes to strengthen before re-installing plate. I found that cutting carbon fiber rod to 2.4 cm works better. Apply thin CA to rod and then insert completely. Then one drop in tiny holes, and at rim. Let dry for at least 1 hour.

Use the last top fifth hole of the servo arm, and the second hole from the top on the aileron's control horn (should give you about 1" on high rates). A computer radio with EPA is required to really set it properly (remember to use low 1/2" rates on first flights). I trimmed a little off the control horn back mounting plate so it didn't hang over the edge. Be careful tightening. Used a little blue Loctite on security nuts.

First, I reversed the carburetor on the Saito. I then drilled a new hole in the firewall for the throttle cable (over about 3/4") to put it behind the throttle arm. Leave about 1/8" of the tube sticking out and epoxy tube in place.

The manual suggests 125mm between the firewall and the front of the silver drive flange. With the Saito 125, I managed to get this down to 130mm. I ground a tiny flat edge on that corner's motor-mount washer, and a little crescent off the motor mount (that's all on the plane, not the engine), leaving 1mm clearance between the engine's black carb. screw and the motor mount. With a smaller engine, you should be able to hit the 125mm mark.

I used the Dremel drill-bit looking cutting bit to cut the cowl. Sandpaper will take off the left-over fiberglass "hairs" (don't sand or scratch paint on outside). It took several sessions to get it right (take your time and don't get in a hurry and take off too much). Tape pieces of card stock to fuse so you know where wood stops after you push cowl into place. Cowl mounting screws should hit plywood (see below for a change I eventually made to the cowl mounting system).

Used a temp. 5mm spacer in front before taping cowl in place (watch painted lines) for pre-drilling with 1/16" bit. Leaving just enough in back to screw down, I ended up with an acceptable 5mm between the front of the cowl and the the back of the spinner.

Note: The pictured red Dubro spinner has since been replaced with an aluminum spinner.

Drill 1/16 holes for 3 rear servos and temporarily install servos with screws to thread the wood. Remove servos and use a toothpick to wick 1 tiny drop of thin CA down into each of the 12 holes. Let dry completely before permanently installing the servos. When epoxy gluing in the vertical stabilizer, don't forget to insert the lower rudder CA hinge. After vertical stab./rudder dries 8 hours, thin CA glue (both sides) of the final lower rudder hinge.

A good size bit for drilling holes for any of the 2mm control horn screws in the model is 5/64. After screwing down with the bases, (not too tight) snug the security nuts down with a 4mm socket, then a little blue Loctite.

I cut the 2 elevator carbon-fiber rods to 95mm, the rudder one to 103mm.

Since the screw doesn't fit the hole, drill a new 3/32 hole in the tail wheel bracket, close to halfway in-between the 2 existing holes. Enlarge the other existing hole to 3/32. Install an extra coupler or spacer on the tail wheel axle to get the wheel to line up with the rudder.

Current progress on plane as of 7-5-2006. Just some small things left.

Final To-Do List:
Enlarge cowl cut-out for glow access - Done 7/12
Install new 4.8v 1500mAh battery - Done 8/15
Install ext. switch and charging jack - Done 8/15
Leak test and secure tank - Done 8/16
Perm. install new wheels, axles, L.G. - Done 8/16
Install EZ Fueler through cowl - Done 8/17
Loctite (8) engine and motor mnt. screws - D 8/17
Finalize eng. throttle throw and EPA - Done 8/17
Install fuel lines and exhaust vent line - Done 8/17
Finalize muffler positioning - Done 8/18
CG balancing - Done 8/18
Surface throws and loctite ctrl. rods - D 8/19
Program in expo. and dual rates - Done 8/19
Applied stickers - Done 8/20
Installed aluminum spinner - Done 8/22

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Balancing

For the proper CG, the battery had to be installed next to the fuel tank (under the cowl). Also, 1.0oz of weight was added on the left, on the firewall. Therefore, my perfectly level balanced (right-side-up) CG is at 95mm (slightly forward of the recommended 100mm).

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Firewall Modifications

After 4 tanks through the plane, 2 of the 4 motor mount to firewall screws came slightly loose (even though they had lots of Loctite and were really tight). Since I used new 8-32 hardware for the engine to mount, I had the M4x30 screws left over. Install these to mount the motor mount to the firewall instead. Where they stick out 1/4" on the back, install a M4 metal nut with nylon insert (aircraft) to lock up against the back of the blind nut.

If you are also running a big engine, you might also want to add some braces like these. I used Basswood because it's fairly strong, light, and the epoxy soaks in nicely before it sets.

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Saito 1.25 Muffler Maintenance

To get the header and muffler from coming loose after every 3 or 4 flights, I wrapped white PTFE (teflon) plumber's tape (5 or 6 inches ... 3 or 4 turns or layers) around the pipe on both ends. Clean everything real good first. Remove extra tape from pipe openings before bolting it all back together. When first back at field, run engine, shut it down, and then tighten it once more while it's still hot.

PTFE Thread Seal Tape (white), Mil Spec T-27730A, 1/2" x 260"
Temperature Range: -450* to +500* F

Also installed extra 1/4" piece of tubing around outside end of tank vent/pressure tubing where it attaches to exhaust fitting on muffler. Fixed engine surging and lower than normal RPMs (by fixing escaping pressure gases between fitting and tubing).

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Attachment of Removable Parts

When attaching wing halves (no matter how finger tight I made them), the nylon bolts would gradually loosen up during a session of 3-4 flights. The fix is to use a washer of non-slip material on BOTH SIDES of the large plywood washers. I ended up using plastic screen material on one side and a large neoprene rubber washer on the other ... no problem since.

Even though I used the CA Thread Procedure on the self-tapping cowl attachment screws, they eventually come loose after a few flights. I re-drilled the holes and epoxied in brass 4-40 threaded inserts (full install instructions on package). Install small wooden blocks (I used Basswood) inside the fuselage so the inserts have something to screw into. I also installed another set of screws closer to the front. Attach with screw, lock-washer, metal washer, and finally nylon washer (against cowl).

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July 2007 Modifications

I decided to install a new tail-wheel with a little more spring action on the axle wire.

You can glue in toothpicks to close the old holes. The pivot point should be even with the rudder hinge. On the Sullivan, I used the heavier of the 2 spring-wires.

I used a plastic "straw" ( like from a can of WD-40 or compressed air) to adapt the thin wire to the proper diameter to fit securely in the 2 back rudder mounts. Take the extra time to do the Collar Mount Procedure to hold collars and 1" wheel on. 3/32" was the closest I could find to the Sullivan's 5/64" axle.

Here is the completed tail as of July 2007.

I liked the idea of placing the remote glow inside. Glued in some blocks to raise the height as to only need to drill through balsa and not structural plywood. Don't drill hole bigger than needed. Mount far enough back so that it will be recessed about 1/4"-1/2". I used (2) No.2x1/2" screws.

Wiring can go through the same holes as the fuel lines. I ran ground wire to an engine mounting bolt.

Use masking tape to tape the template (made from card stock or heavy paper) into place. Then install the cowl with most screws (leaving template on the outside) and use a fine marker to trace the exact hole you need to cut in the cowl.

Above is also a good shot of the brass 4-40 threaded inserts epoxied into place in a previous mod (they work great by-the-way).

The end result is a refreshing change. The old way was a little awkward because the glow plug was pointing down to the ground and was mostly hidden from view when standing above plane.

Feb. 2008

Added 4 small pieces of fuel tubing to the 4 horizontal stab. bracing rods in back to keep them from vibrating and enlarging the holes on the metal straps.

Checked that 4 clevises (on other end) were snapped tight and safety tubing on clevises was still good.

Futaba 6EXA-S	Low		High		Dir	D/R-L	D/R-H	EPA	Trim
1 Ailerons	1/2"	1/2"	1"	1"	Rev	45%	100%	L 85 - R 100%	-32
2 Elevator	3/4"	3/4"	1-1/4"	1-1/4"	Rev	55%	100%	D 85 - U 100%	+12
3 Throttle					Rev			D 115 - U 85%	-20
4 Rudder	2"	2"	3"	3"	Nrm	70%	100%	L 85 - R 100%	-16
Expo	-20%		-30%			CH 1,2,4	CH 1,2,4

On 6EXA (older model): For CH 4-Rudder, No D/R or Expo available. So, for 2-1/2" full-time EPA L 70% - R 77%

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Activity Log
Date	Field	Type	Equipment	Details
8/23/2006 Wednesday	ARCS AMA field		Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	Ran engine at field (with plane on test stand) for 3 tanks.
8/24/2006 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	Maiden flight. Trimmed out plane and flew it easy around the field for about 10 minutes. Good landing with taxi back to pits.
8/25/2006		Repair		Installed longer motor mount bolts and nylon insert nuts to help lock it tight (see Firewall Mod. above)
8/26/2006 Saturday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - 1 good landing, 1 fair
8/29/2006 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - 3 good landings - Here's a picture after 6 flights
8/31/2006 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - 3 good landings
9/4/2006 Monday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 2 good landings, 1 fair
9/6/2006		Repair		Installed PVC tape on header pipe and wire clamp on exhaust fitting (see muffler maint. above)
9/7/2006 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 3 good landings, 1 poor (grass landing ... bent gear) Note: After 4 flights today, found all nylon wing bolts very loose, and one had fallen completely out and was found inside tail section ... need fix to prevent this.
9/16/2006 Saturday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Single loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 3 good landings
9/19/2006 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. 1 extra landing. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 1 good landing from North 2 good landings > South (less used dir.) 1 fair landing from South
9/19/2006 Tuesday		Repair		On today's last flight the muffler came loose, at lower pipe connection (after 10 flights). Completely removed pipe and repeated securing procedure. Rubber and/or plastic screen washers (2 on each bolt ... both sides of large wooden washer) seems to have fixed wing bolts coming loose.
9/26/2006 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. Flew some maneuvers with High Rates for the 1st time with this plane. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 3 good landings from North
10/7/2006 Saturday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. Flew some maneuvers with High Rates. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 4 good landings from North
10/23/2006 Monday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 3 good landings from North
11/3/2006 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 2 good landings, 1 fair from North
11/4/2006		Repair		Installed 4-40 brass threaded inserts to hold cowl on better.
11/14/2006 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Knife Edges - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Inverted flight - Split S - Snap rolls - 2 good landings, 1 fair from North
11/24/2006 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edges - 2 good landings from the North
12/12/2006 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 3 good landings from the North
1/12/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edge - 2 good landings from the North
2/6/2007 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edges - 6 good (and 2 fair) landings from the North (including Touch-and-Goes)
3/2/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 good (and 1 poor) landings from the North
3/23/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops (single & consecutive multiples) - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 good (and 1 poor) landings from the North
4/5/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. Made extra landings. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 4 good landings from the North
4/11/2007 Wednesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. Made extra landings. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 3 good landings from the SOUTH
4/17/2007 Tuesday		Repair		Made the following repairs: - Replaced missing Saito valve-cover screw. Checked other engine screws. - Repaired leaking fuel tank (tightened stopper screw). Checked all tubing. - Re-glued loose throttle push-rod tube. - Replaced worn throttle servo arm push rod holder (E/Z Connector). - Re-glued right rear firewall brace. - Tightened all servo screws and checked linkages.
4/26/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 good landings from the North
5/10/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 good landings. (One from the North, the other from the South)
5/30/2007 Wednesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers (with extra landings). - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 4 good landings from the North
6/12/2007 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 good landings from the North
6/14/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 4 good landings from the North (1 extra)
7/10/2007 Tuesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Touch and Goes - 8 good landings (made extras)
7/24/2007 Tuesday		Repair		Made the following repairs and modifications: - I heard something rattling around in tail section. Found 2 pieces of the forward fuel tank mount in tail. Removed tank. Cleaned off old glue from all pieces and lightly sanded. Re-epoxied 3 piece plywood mount into place. - Installed Sullivan Remote Glow. - Installed new tail-wheel assembly.
7/28/2007 Saturday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Touch and Goes - 5 good landings (made extras.)
8/10/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 5 good landings (made extras.)
8/27/2007 Monday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight (1 pass at 15ft.) - 4 good landings, 2 fair (made extras.)
9/6/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 4 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Touch and Goes - 6 good landings, 1 fair (made extras.)
9/20/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edge (attempts ... practicing) - Touch and Goes - 5 good landings (made extras.)
10/3/2007		Repair		Performed the following maintenance: - After a year or so of easy flip-starting it now won't start on the first couple of flips any more, and sometimes I even have to resort to using starter. - Replaced Saito glow-plug with OS-F type 4-stroke glow-plug.
10/5/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. (Started on 1-3 flips ... back to normal). - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edge (attempts ... still practicing) - Touch and Goes (3) - 3 good landings
10/11/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. (Engine won't flip start again. Started backwards even with starter ... weird). - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Knife Edge (attempts ... still practicing) - Touch and Goes (2) - 2 good landings. 1 fair from South (less used direction) in cross wind.
10/24/2007 Wednesday		Repair		- Adjusted Saito 125 valves to spacing of gauge that came with engine (.004" or 0.10 mm). Before adjusting, I noticed they were out of adjustment (too much space). Hopefully this will fix starting problems and provide more power (by opening valves further). Adjust valves with cylinder at TDC. If glow plug is left in, TDC is one complete counter-clockwise turn from where BOTH valves are open equally. - Also cycled and charged 12v field battery and 1.2v glow starter battery.
11/2/2007 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. (Engine won't flip start, but starts OK starter. Engine has more power). - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - Touch and Goes (2) - 3 good landings (made extra).
11/9/2007 Friday	RiverCity AMA Field	Flight	Futaba 9c OS 160	*Total of 1 flight:* First time flying at RiverCity field (flew as guest). - Flew Mike B.'s Goldberg Obsession (because my Edge wouldn't start at all) off of their grass runway. First time flying a large plane like this. Took it easy since it wasn't my plane :-)
11/24/2007 Saturday		Repair		- Starting problem was defective Sullivan Remote Glow Connector. Intermittent connection needed vibration of starter to make a connection. When they built it, they crimped the wire so hard it broke loose after about 20 flights (at connector where glow igniter attaches inside fuselage). Repaired and soldered wire this time. Checked with Ohm-Meter. - Forward fuel tank mount came loose again. Re-sanded parts and re-glued with Gorilla glue this time. - Applied thin coat of red RTV silicone (and let it dry first) to all 8 cowl screws before installing. Trying this instead of wrapping each screw with teflon tape.
11/28/2007 Wednesday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 3 flights:* Performed the following maneuvers. (Engine started on first flip, all three times ... no starter needed). - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Split S - Snap rolls - Inverted flight - Touch and Goes (2) - 6 good landings (made extras). 1 poor.
12/20/2007 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Byron 15%	*Total of 2 flights:* Performed the following maneuvers. (Engine started easily by flipping both times ... no starter needed). Very windy. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 2 fair landings (from South ... less used dir.).
1/10/2008 Thursday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Omega 15%	*Total of 2 flights:* Performed the following maneuvers. - Low (full-throttle) high speed passes - Loops - Rolls - Stall turns - Immelmans and 1/2 cuban eights - Split S - Snap rolls - Inverted flight - 3 good and 1 fair landings (from South ... less used dir.). On last flight, was flying fast, low and inverted toward myself over runway. Somehow, I guess I forgot I was inverted and went down instead of up. Within a few feet of the ground, aileron rolled plane right side up, and did an Immelman to gain some altitude and change direction. Plane was going pretty fast the whole time. Definitely the closest I have come to crashing my Edge (or any plane for that matter in the past couple of years). After a few easy times around the field to catch my breath, I came in for a nice easy landing. Note to self: After not flying for a few weeks, take it easy on the first few flights :-)
2/8/2008 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Omega 15%	*Total of 2 flights:* The first flight was an easy flight to get comfortable flying after not flying for a month. I did all my usual maneuvers (as listed in above flights ... including inverted :-) and also practiced my landings. However, I noticed the plane was out of trim for some reason, so I made some trim corrections (which I don't usually have to do). After landing, I put it on the table and checked it over. Everything looked fine except I did adjust the dual elevator servo-reverser (inside the plane) to get them synced a little better (since this had also fell out of adjustment ... more strangeness). The second flight started out by more trimming. Fixing the elevators had helped, so I took out some of the trim I had used to compensate during the first flight. I worked in most of the usual maneuvers, and kept checking the trim at various speeds including plenty of full throttle. Time must have gotten away from me and (not knowing it at the time) I had been up about 14 minutes. As I passed over the runway at about 40 feet (not really trying to land or anything) the engine just died. In just one second of gliding downward I was already out of runway and still pretty high. Heading for the "Rock Garden" section of our field, I veered-off and headed for the rough weedy area (the better of the 2 places). It sounded pretty bad as it tore through the high grass and dead thorn bushes. It came to rest here, right before hitting the small trees or going into the ditch. I ran out to retrieve it and was very happy to find it in one piece (but nosed over). Here is the plane right after the landing. I checked it over pretty good, and the only damage (including the covering) appears to be the bend front landing gear. On this plane, the stock landing gear is "soft" which is a good thing as it probably saved the airframe from more damage. As I tried to de-fuel the plane and pack-up, I found the cause of the dead-stick ... I had ran completely out of fuel. This is my first dead-stick with this plane/engine but even a Saito won't run without fuel :-)
2/27/2008 Wednesday		Repair		Removed landing gear and bent back into shape. Everything else looks ok (fuselage, gear mount, motor mount, etc.). Did tail-wire tubing mod. (see above). Reinstalled cowl and charged up batteries.
2/29/2008 Friday	ARCS AMA field	Flight	Futaba 6-Ch Saito 125 15x6 MAS Omega 15%	*Total of 1 flight:* Another surprising day at the flying field. Plane started right up (flip start) and I flew around and did my usual maneuvers. Plane still flies like it's out of trim, so I tried trimming it more. I landed nicely, but was going too fast at the end of the runway to turn around safely, so I gunned it and took-off again. The cross wind was now 15-20 mph but I had to land because I was running out of time (fuel). Keeping the throttle up to fight the cross-wind, I landed poorly. On touch-down it broke off the right front landing gear leg. It veered off and came to rest in the grass. Fuel tank was basically empty. Landing gear appears to be the only damage.
		Repair		The blind-nuts on the right side tore clean through. Replacing landing gear mount.

Additional Links for Seagull Edge 540

Manual
RC Universe Review
Martin's tricked-out Edge 540
Dave's Edge 540 Build
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