For a few years I've wanted to do a VS Sailplanes VMax scaled down to a 60" wingspan. My wife finally kicked my butt in gear, after listening to me all this time talking about alot and not doing much.

I like to use laminated layers to do my plugs because each layer gives me a guide to sand to. I can finish a plug with almost perfect symmetry and with out the use of templates quite easily and quickly this way.

I used to do my laminations vertically with copies of left to do the right side but you can easily end up with a bend in the plug, so now I do it this way, horizontally. Bend from side to side is less likely, however you now run the chance of puting a bow in the plug longitudinally, but I think that is alot better to deal with than an bent fuse.


1. I modeled it up in Rhino.
2. Placed horizontal planes in 1/8" increments the height of the fuse.
3. Laid in some 1/8" rods for alignment purposes.
4. I then used the intersect tool which gave me the outline of the fuse at each of these heights.
5. Next I took each of these layers and spread them out on 1 plane.
6. Labeled each part. Set this aside, oh and made a copy.
7. Laid out a plane that would be the stock that would be laser cut and made copies of these.
8. Start nesting the outlines from the intersect onto the stock planes ( I had to do staggered cuts to the length of my pieces to accommodate the available stock and cutting area of the laser. Make sure you...Continue Reading