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Old Apr 18, 2009, 02:29 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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FoamEdge by Billy Haynes

This is my own Foamie Edge design. I started it around June 2004 and kept modifying it. The goal was to make it lighter without sacrificing strength/durability and to maximize it’s flying ability. The following is the latest design (and probably the last). I have made molds for the landing gear and elevator support. If you have any questions ask.
W.S. 36"
W.A. 300 sq."
Length 30"
3oz-3.75oz airframe weight depending on material used.
A.U.W. 12oz-14oz depending on material and equipment used.

The plan is 36" x 40" for ease of printing at Kinkos, ect.
Building instructions done in Mocrosoft Word saved as Document (.doc)
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Last edited by Billy Haynes; Apr 23, 2009 at 05:12 PM.
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Old Apr 18, 2009, 02:57 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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Make a kit of parts
1- Cut out foam parts.
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Old Apr 18, 2009, 03:04 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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2- Bevel all control surface leading edges at 45°.
3- Cut 1/8” groove for leading edge spar, secondary spar, and elevator joiner spar with a 1/8” router bit.
4- If cut from two pieces of foam, glue wing panels together with any foam safe glue you prefer.
5- Glue elevator joiner spar and elevator trailing edge support with epoxy or foam safe CA.
6- Glue leading edge spar and secondary spar into the wing with epoxy or foam safe CA
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Old Apr 18, 2009, 03:09 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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7- Hinge ailerons and elevator. I prefer Blenderm made by 3M.
8- Glue elevator assembly/rear horizontal fuse to trailing edge of wing.
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Old Apr 18, 2009, 03:14 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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9- Glue lower vertical fuse to bottom of wing/rear horizontal fuse.
10- Glue front horizontal fuse to the wings leading edge and lower vertical fuse.
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Old Apr 18, 2009, 03:35 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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11- Glue top vertical fuse to wing/horizontal fuse assembly.
12- Trim vertical stab for elevator clearance if required. (You want to have 45° of elevator travel)
13- Hinge rudder to vertical stab.
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Old Apr 18, 2009, 03:52 AM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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14- Install servos. Servos go on bottom side so as to be less visible.
15- Install cont. horns in line with servo arms.
16- Install .032” control rods. For 3D flying, elevator and rudder control rod guides should be installed. Control rod guides can be made from Sig Mfg. Giant Scale Hinges.
17- If molded landing gear and skid are to be used install it now.
18- Install RX, sped control, motor and battery to achieve a CG 3” from leading edge.
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Old Apr 18, 2009, 05:44 AM
To Build? or Build Another?
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Los Angeles, CA
Joined Feb 2009
145 Posts
I really like the way you made the wheels! I always get stuck with how to mount it on the frame.. but thats brilliant thanks for showing it.

It also gives me a great idea for bracing wings and making them removable too.

I have some time this weekend. I might give it a go.

Cheers.
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Old Apr 18, 2009, 07:11 PM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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The plan was drawn in ViaCAD. Plan is 36"x40".
Here’s a zipped folder of the drawing.

If you want it in another format let me know and I'll see if I can convert it into the format you need.
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Old Apr 18, 2009, 07:16 PM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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If you want to make the landing gear form, here’s the plan.
I use C-clamps to press the two forms together.
I tape a piece of clear plastic wrap on the workbench with the plastic nice and smooth and lay up the glass on it. Then I put a top layer of plastic wrap on the lay up and squeegee the air bubbles out. Usually turns out pretty good.
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Old Apr 18, 2009, 07:35 PM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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Here’s the elevator support form drawing.
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Old Apr 18, 2009, 07:37 PM
To Build? or Build Another?
genetix's Avatar
Los Angeles, CA
Joined Feb 2009
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Billy, thanks for the forms and the structure, thats great!

I don't have any program to open your files. My programming days are outdated... got anything in a pdf form or similar? Thanks!

Cheers
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Old Apr 18, 2009, 07:48 PM
AKA BillyKillaWatt
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Rockwell, NC
Joined Jan 2002
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From ViaCAD I can export to the following:
ViaCAD, ACIS SAT, Adobe Illustrator, BMP, CGM, DWG/DXF, EPS, IGES, JPG, STEP, Text, Viewpoint Media, Wavefront OBJ.
I do not claim to be a comp. whiz. I do good to just get stuff drawn
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Old Apr 18, 2009, 09:04 PM
To Build? or Build Another?
genetix's Avatar
Los Angeles, CA
Joined Feb 2009
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EPS and JPG would be our best bets I think. A JPG could show us the drawings and EPS means we can resize it to any size. Thanks

Cheers
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Old Apr 19, 2009, 07:16 AM
Crash Master
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Indianapolis, IN
Joined Sep 2001
16,632 Posts
.dxf is a universal vector format. You don't lose resolution when you scale. It can be imported by most decent vector-based programs, like CAD and such.

.jpg is bitmap based with a lossy compression. It's fine for pictures, but for black and white vectors, it's a bit poor to scale.
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