Hot wire melting of about 24 chunks of EPS.
Then glueing together.
I made a 3D model of the plane, and printed a bunch of corresponding cross sections.
These templates are cut with a knife, and glued of the front and back end of a eps chunk.
Then i pull the hot wire against the templates, by doing this i have both the outer and inner construction and design.
Take a look at my blog, it explains itself pretty much.
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