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Old Nov 27, 2006, 10:45 PM
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Joined Nov 2001
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I first got the fuselage plan and side profile templates cut from cardboard. I used 2 sheets of 2" pink foam and tack them side by side together with a coat of 3M77. This is the only adhesive I've tried that allows hotwire cutting through the joints. I hotwire cut the foam block edges square before pinning the plan profile templates on both top and bottom. After cutting the 2 side surfaces, I tack the foam beds back with 3M77 to form back the foam block. This will help to align the side profile templates for hotwire cutting the top and lower surfaces.

Another template was fabricated and pinned on the foam to cut the canopy out, before a hole was bored through the centre on the fuselage for the wing joiner tube. After that, all the waste foam beds were removed and the fuselages were carved and sanded to shape.

The fins were also hotwire cut using conventional hotwire cutting method.

Sorry, I didn't take much pictures up to this point.
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