Originally Posted by carrid02

No, I don't think it's ACME thread. I'll take some closer up pics and post them. I'll also take a picture of the bag of wire I use.


For foam cutting, I use various bows (big and small) but for making smooth/long/controlled cuts, I'm borrowing one of my friends setups. (pictured)


Kinda hard to explain how it works, I'll just have to make a video and post it to youtube. Needless to say, it makes awesome/accurate cuts.


-Craig

Whoa! That's cool! One man operation. Looks like the counterweight controls how much force is on the wire to template and has a device to keep the bow perpendicular to the templates while it pivots from one side of the cut to the other. Damn, someone had a wet dream when that was thought up!!!!! Would love to see a video. Thanks for sharing!
Paul
Edit: not really perpendicular but to make sure the wire starts and stops on each end of the templates for varying length templates. Perpendicular if templates are same length on each side. WOW!!

Yes, you’re right... there’s actually 3 major systems to this foam cutter:

1. the counter weight on the main bow is adjustable so the bow only applies light downward pressure on the foam being cut.
2. Then there’s a pilot arm that’s adjustable so the bow ENTERS the cut parallel to the foam and EXITS the cut parallel to the foam. This is critical so the hot wire cuts a continuous straight line through the curve of the wing.
3. Then there are 2 weights on pulleys attached to the workbench out from the leading edge of the wing and the trailing edge of the wing. These are used to automatically pull the hot wire THROUGH/ACROSS the surface it’s cutting.

That’s the long explanation... Here’s the short version: once everything is setup... all you do is turn power ON to the wire and the cut occurs ALL BY ITSELF. Pretty freakin cool.

-Craig

Once I get the foam cutter setup, I’ll be cutting several sets of wings and stabs. I want to cut some solid foam core (obviously) but I also want to cut a set of wings using the blue foam method pictured.

-Craig

Thanks Craig. I look forward to seeing the progress. I just built another bow but this is a bit new still.

So I finally made a few cuts on foam this morning! I cut the end off my big block and cut a “blank” for stabs. Still need to make a few templates and cut it down some. Foam cuttin is fun fun!!!

-Craig

Nice! Thanks for the pics

The lower deck has been glued on! I also finished out the rear hatch and have started sanding. Also, both 1/4” balsa caps have been added to the front.

-Craig

Looking good Craig! I like the tail wheel detail. Nice and clean.

Scott

Thx! I’m really trying to streamline everything as best as possible.

-Craig

WOOHOO!!! Bottom deck is 100% complete and I’ve officially flipped the fuselage over!!!

Now I’ll get the stabs done and incidence set, then I’ll do fin/rudder/rear upper deck!

-Craig

Clean build, looks great!

Thx Mike! Started cruising on the stabs over the thanksgiving break... updates on that soon!


-Craig

So, I’ve started working on stabs. I’m getting these cut out and sheeted before I jump on the rudder/fin and rear deck.

Couple blanks done!

Got the templates made and cut out some stabs!

-Craig

Awesome! Thanks for the pics of the process. I like how you have the aluminum templates that are laid over a set of plans to make the blanks. What are you using to hold the templates against the foam? Screws?
Paul