How to Cut Foam Wing Cores for Model Planes

Model planes are a terrific hobby for those who love planes and enjoy building things with their hands. Most model planes are built using balsa wood and other light materials, but foam is also a very popular construction component. Foam wing cores help make building model airplanes easier by reducing the need for construction of the entire wing. With one cut you can have foam wing cores ready for flight.

Difficulty: Easy

Instructions

Things You'll Need:

• Foam
• Hot foam cutters
• Wing design

1. Determine the wingspan you want your wings to be. The larger your wingspan the more lift the foam wing cores will generate and the more easily your model planes will fly and glide. The average wingspan for model planes falls between 24 inches and 48 inches.

2. Lay your foam out lengthwise on your workspace.

3. Secure it to the table using dowels or anything that won't get in the way while you are cutting.

4. Draw an outline on the outer edge of the foam using a template. A permanent marker should do.

5. Place guides along the length of the foam to help you maintain the right cut as you proceed. Wood runners are typically the best.

6. Turn on your foam cutter and give it a few seconds to heat up. Typical foam cutters only take between 10 and 30 seconds to heat up.

7. Line up the foam cutter to the template.

8. Cut the foam down the length of the template, remembering to keep it against the guide block as you go. Move quickly but carefully!

9. Adjust the foam for each successive cut, raising or lowering the foam to bring the outline of the template in line with the foam cutter.

10. Sand down the rougher edges of the foam once you've completed all of your cuts. The less bumps and burrs on the control surface the more accurately your model plane will fly.

Tips & Warnings

• You can always pay to have foam wing cores cut for you by a professional foam cutting service. Many professionals offer a wide selection of pre-designed foam wing cores so you always have a few choices available to you. Also, while you can cut your own wings relatively accurately, professional foam wing cores are cut with even more precision.
• Don't let heat build up on any one spot of foam for too long or the heat will simply bleed through the surrounding foam and ruin the cores you are trying to make. Always move the cutter as fast and firmly as possible.