Hi,
After the wing root template is made, you then have to go about checking the template against the actual plans. I look at this as a reality check in that it doesn't matter if you made one 1 mm error, that is one too many. The first picture here shows the reality check of using the drawing and comparing it directly to an actual line drawing made from the kit part. This usually shows up any error in the copy process, but in this case, I was very please to see that the error was less than the fine point pens I'm using. When it comes to making templates for the AMAP foam cutter, I use two templates per wing root and wing tip. In other words, there is a template that cuts the bottom half and a template that cuts the top half. If you look at the next picture, you will see the 3/16"plywood wooden template that is used to make the formica template. Why wood first??? Because there are usually a LOT of error involved in using carbon paper to transfer a plan plus carbon paper doesn't stay on formica very well. You can't use a stick pin method to transfer the pattern because formica is too hard. Making a wooden template first may seem like added work, but it makes making the formica templates very easy plus before you make the formica templates, you can be absolutely certain that the airfoil shape is correct.

The next picture is of my AMAP foam cutter. If you look at the picture, you will note that the cutter has infinite adjustment as to rake/sweep and really does a sweet job of cutting foam. You can see the Variac transformer in the top right corner. You will find that having very fine temperature control makes cutting uniform cores simple. This would mean that the larger foam wing you are cutting, the more power you will use in the resistance wire (Nichrome)...Too much, and you will literally cause a meltdown of the foam, too little and the wire will not cleanly cut thru the foam.

Couple of comments on the foam I use. I only use 1 LB per cubic foot CLOSED CELL FOAM. You will find that you can buy open cell foam cheaper, but that it is not as strong or uniform in weight. To tell the difference, look at the side of the foam.. if you can see individual "honeycomb" sections, then it is closed cell. If it is just a mass of foam, then it is open cell. Again, this is not the place to save money on a pattern ship.

I have also posted pictures of the templates versus the plans and am trying to give you folks an accurate picture that you simply have to take your time doing this. If done incorrectly, you have the wrong airfoil, at the wrong size, and cut incorrectly. Also posted is a picture of my bandsaw with a very easy way to make a rip fence. This way you can get an very straight cut on your template material before starting.

For those who would like a set of plans and cores for this project, please send me an email at [email protected]
Seperately, the plans are $20 shipped (rolled in a mailing tube).. you never fold plans.....and the cores are $55 plus $10 shipping...The plans plus the cores are $75. So save ten bucks and get the set.