RE: Hot wire foam cutter
I'm glad you found the article helpful.
The foam core is cut to the planform then the airfoil shape. Make sure you cut the bottom of the airfoil first then the top or your airfoil will be thinner. Then you prep the core with spars slot, holes for servo wires, etc.... Then you apply the skin of your choice; ie. composite material, balsa using epoxy, gorilla glue etc...
I can give more details later but it's all shown and much, much more in my instructional DVD.
Curtis
Montana