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Old Sep 23, 2003, 11:01 PM
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Foam cutting templates

What can I use for foam cutting templates. Plywood? Cardboard? Aluminum?

I'm working with dremels and hand tools here, so I'd kinda like to stay away from any metal that can't be cut by hand.
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Old Sep 24, 2003, 05:24 AM
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Luan plywood makes good templates, it is cheap and easy to fabricate. I have one of the nice little bench top band saws.. great for cutting the luan and foam..
1/8 inch Aluminum would be great, if you could make them... a CNC laser cutter would be great to make them.. hehe!!
I have used the luan templates to make wings and tails for my Lazy Blue foamies...

Hope this helps
Carl
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Old Sep 24, 2003, 10:15 AM
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Templates for foam cutting

I found that 1/8 inch formica works very well.Formica is what counter tops are made of can get it at about any hardware store.

Luke..
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Old Sep 24, 2003, 10:46 AM
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Roof flashing can be cut with tin snips and the edge polishes up pretty good with a Dremel. the wire catching on the little snags in wood or even formica make for a corrugate wing.

CTF
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Old Sep 24, 2003, 11:06 AM
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templates

Do you have a printers shop nearby?

Since I have friends in the graphic industry I have been using the thin aluminium plates that is used for offset printing. They can easily be cut with a good pair of scissors (don't use them for anything else... ) Most printers will be happy to give you a few they do mistakes all the time!

I print my wanted airfoil on paper, glue this to the litho plate and cut out. Just a light sand with 400 grid sandpaper and I'm ready to go. I use needlepins to secure the template on the foam, just press it through the template, and I'm ready to go!

Works fine for me

Ben_E
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Old Sep 24, 2003, 12:36 PM
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I use thin posterboard. Cheap, easy to cut out and has so far held up well to the heat.

You just cut it out with an exacto.


Dean in Milwaukee
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Old Sep 24, 2003, 12:47 PM
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I use poster board primarily, but you can only cut a few set before they have to be replaced. I have used, luan or other ply woods, but san the edges for burrs.

If you are cutting wing cores, you will want a more ridgid structure than posterboard will provide so use ply for that

Anything non plastic works very well.

Kirby
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Old Sep 24, 2003, 08:44 PM
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Thanks Gents. It's off to the hobby/hardware store once again. I just got a little hotwire rig going and have collected a room full of foam.

First project: Warmliner. Maybe based on the AZ Shrike, but without the bluecor.
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Old Sep 24, 2003, 11:05 PM
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the best technique i've used, is to cut them out of wood, even hard balsa works. sand the edges smooth, coat edges with ca. sand again, more ca, then final sanding. very smooth and no catches
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Old Sep 24, 2003, 11:40 PM
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Print Shop

Thx Ben,

Never even thought about that! And I used to work in a printshop..LOL Gonna have to stop in and visit them REAL soon
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Old Jun 28, 2016, 10:01 AM
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I use a CNC router to cut Formica/Masonite templates.

Phenolic is even better material, but much tougher to find. Lasts the best.

BTW if anyone needs custom airfoils in custom chord lengths let me know ? $35.00 for two bottoms and two tops, out of Formica.
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Old Jun 30, 2016, 04:14 PM
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This thread is 13 years old I doubt anyone is still around.
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