Introduction

The EDGE 540 is a well known scale plane, often seen flying in various shows and scale events. The following presentation shows some great modifications made to this scale electric kit, which make it not only a light plane, but also add to it’s already amazing appearance. This specific kit is sold by Radical RC ¹.

Top down modifications

Tail

Cut out as much of the “tail group” as possible: Drill holes into the tail surfaces (Diameter?) to reduce the amount of material in it. The covering will have no problem on this flat surface.

Wing

The wings are made out of foam. Tape the wings into the cores so they wouldn’t move. Put the wings on to a Dremel jig saw and bore a hole. Pass the saw blade thru it and cut out the rib bays. This could cut close to half the weight. Covered with nelson film (at .6 oz per sq ft it didn’t add a lot). I believe a built up wings and tail feathers will be lighter and stronger.

Fuselage

Don’t make the mistake we did and drill the nose! this weekends the structure and thus actually adds weight in the end by having to add a carbon fiber rod. We added small diameter carbon fiber rods spliced in half down the length of the fuselage on both sides, as the plane would twist from torque when it went to full power.

Landing gear

The carbon fiber landing gear was formed from a piece of blue foam cut to the shape of the stock wire gear profile. Use wax paper and sandwich the foam, using 1 layer of 1/64 plywood and 3 pieces of carbon fiber tape, 2 layers on the outside 1 layer on the inside. Use thick C.A. and press it into the blue foam mold and put it in a vice for 10 minutes. Pull it out and cut it in half-length wise. It is easier to build two at a time because they will come out the same. I also used dubro 1½” indoor wheels as they are only a few grams. also make sure to use wax paper on the landing gear.

Control horns

I made up carbon fiber horns with only two layers of carbon fiber tape. I used 2 pieces of wax paper and then pressed it between two boards using thick C.A. ;

Flight gear

I found that an APC 9 1/2 X4 indoor prop seams to work better as it gives more pull. I flew it outdoors and it flies excellent. The JETI ECS does not working well with this setup due to the cut off it has on it, so I have replace it with a new Great Planes Electrifly C-20 and it seem to do the job. Also the 750 mah nickel metal hydride batteries from Radical R/C are super and save a lot of weight (They are the only batteries you can use for hovering because ni-cad would be too heavy; to have than 1:1 power ratio).

Flying

The Edge 540 was successfully flown indoors . It would do rolls, and even harrier landing. Remember, it takes a very good pilot…

Model details

• Servos: Cirrus CS-10BB
• Motor: Speed 280/300
• Prop: APC 9 1/2 X4 indoor prop
• Receivers: CSI mini 4-channel
• ESC: Great Planes Electrifly C-20
• Battery : Radical R/C 750 mah Nickel Metal Hydride (NiMH)
• Total Weight W/Battery: 8.8oz!

I hope this has been helpful to anyone who has a Radical R/C Edge 540 or who is thinking of scratch building one. I have started to build a 300 EX with 3 D modifications (The Stab moved forward, bigger counterbalances, bigger control surfaces ect.)