Back to the Buccaneer.
With the CAD model of the fuselage complete, I could start on the plug construction. My plan was to build thin bulkhead cross section templates and fill out between the sections with sheets of blue foam. The fuselage plug was going to be assembled on a 2" square metal fence-post as a structural member, with additional 3/8" tubes to act as alignment guides. A wooden support fixture was built to hold the entire fuselage at any angle for ease of working on it.
The inner wings where they blend into the fuselage, along with the forward and aft sections were to be 3D printed.
After measuring a stack of 1/16 ply and blue foam to get the correct spacing, I sectioned the CAD model and produced a series of ply bulkheads, nearly 50 in total. These were laser cut, including the holes for the support and guide tubes.
