Styrofoam insulation as building material - Page 4 - RCCanada - Canada Radio Controlled Hobby Forum
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Old 12-23-2005, 04:01 PM   #31
Ken Currell
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Good description for cutting foam wings

That's how I do it, but I find it better to do it with two people.

I don't like doing it alone as I have to look back and forth as I cut to see if I am on the same mark on each side. Unless it is a small wing I can't see both marks at once.

With two people doing it we call out the numbers as we go.

If I am on number seven then so should the other person.

That way the wing is cut to the proper shape.

It's really important to do this if you are cutting a tapered wing.

For washout I raise the trailing edge of the wing rather than drop the front.

That way the front of the wing in straight and true.

By dropping the leading edges on a straight wing you are building in a slight amount of anhedral.
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Old 12-23-2005, 04:04 PM   #32
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Hey, that sounds like a good idea. I dont know why I didnt think of that! I can probably do that right now with the stuff I have. Ill give that a shot when I am back in town. Until I make my CNC that might be the way to go, I am not sure when I will be able to get the parts for the CNC.. its a little on the expensive side at the moment.

For the templates can you use styrofoam with an epoxy coating to keep the foam from melting? There shouldnt be too much heat energy at the tips like that - enough to melt epoxy anyway.

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Old 12-23-2005, 04:13 PM   #33
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Afraid it will melt the epoxy, Steve, Even plywood doesn't last long. I would guess the wire is between two fifty and three hundred degree.
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Old 12-23-2005, 04:20 PM   #34
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That's why I use Arborite.

I cut close to the line and then use the disc sander an sometimes a file for spar locations.

The finished foam core will be smaller than the templates.

Check it out as setup on each bow is different.

Once you find the right setting on the variac for the bow you are using mark where the pointer is so you can duplicate it later.

That way you only do the setup once.
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Old 06-14-2006, 10:59 PM   #35
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cutting foam wings wich are tapered can be done if you can synchronize de speed of the wire from the root rib to tip rib or vice versa and using a bow with tensioner and an adjustable power supply ,the rigth temperature should give you angel hair inside the core no smoke should be visible; work in a well ventilated room, i don 't think polystyrene fumes are good for your health,and provided that the template or templates are positionned at the rigth coordinates on the cores to be cut . remenber that the greater the taper ratio the slower the wire will be on the tapered(wing tip side) the more radiant heat per square inch or square centimeter of area the wing core will be exposed the less accurate the wing coordinate profile will be . you can always find nickel chrome alloy wire in hair dryer the broken ones of course the tinner the better but ther's a limit.
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