GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
09-14-2004, 09:35 PM
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GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
Hi guys
Just wanted to share some pics of my latest scratch design/build project. I am making a 96" span Spacewalker II out of foam, everything from fuse to the tail surfaces and of course the wings. I really enjoy working with foam and have built many planes from foam using some tried and true techniques I've developed. I use the FeatherCut foam cutting system to create all the foam parts. The plane has 1536 sq inches of wing area, the fuse is 56 inches long, not including the cowl and rear stabilizer. All up wight should be around 12-15 lbs depending on my eng choice. The airframe will weigh around 9 lbs without equipment. The wings are a plug in type for ease of transportation.
Basically what I do is to cut all the foam components and create a "kit", like shown in the pictures. I've attached a picture of all my templates that I've made to create the Spacewalker II. I've cut a spar channel in the foam wing panels before the wings are actually cut from the 6 inch foam block. The fuselage is split down the middle and divided into 6 total sections, each one cut out separately and the glued together. You can see in the pic that the left side of the fuse is already glued together. The tail section is essentially flat foam pieces glued to balsa edging to creat a "frame" that will be sheeted later and edge shaped.
From here I will start the sheeting process. The wings I will sheet using the Pro Bond polyurethane glue, that way all I have to do is
tape balsa sheets together and spread the glue onto the sheets. No need to pre-glue your balsa sheeting here, as the glue expands it will fill in the edges along the sheets and leave very mininal sanding. The cores will be put back into their foam beds and clamped and let sit overnight. The fusealge halves will be joined and I will sheet the inside of the fuselage first, install my bulkheads and cross grain the open bay along the bottom of the fuse. Then I will sheet the outisde. The adhesive I will use is a water based contact adhesive that is available from a couple of sources. It's odorless and give a permanent bond after it dries.
I will post pics as I go along. The techniques are very similar to those that Jack Devine Models uses. They wall work great and create a wonderfully strong but light weight plane that flies great.
Hope you enjoy the pics and i will post more as I go along.
Thanks for looking.
Tom
Just wanted to share some pics of my latest scratch design/build project. I am making a 96" span Spacewalker II out of foam, everything from fuse to the tail surfaces and of course the wings. I really enjoy working with foam and have built many planes from foam using some tried and true techniques I've developed. I use the FeatherCut foam cutting system to create all the foam parts. The plane has 1536 sq inches of wing area, the fuse is 56 inches long, not including the cowl and rear stabilizer. All up wight should be around 12-15 lbs depending on my eng choice. The airframe will weigh around 9 lbs without equipment. The wings are a plug in type for ease of transportation.
Basically what I do is to cut all the foam components and create a "kit", like shown in the pictures. I've attached a picture of all my templates that I've made to create the Spacewalker II. I've cut a spar channel in the foam wing panels before the wings are actually cut from the 6 inch foam block. The fuselage is split down the middle and divided into 6 total sections, each one cut out separately and the glued together. You can see in the pic that the left side of the fuse is already glued together. The tail section is essentially flat foam pieces glued to balsa edging to creat a "frame" that will be sheeted later and edge shaped.
From here I will start the sheeting process. The wings I will sheet using the Pro Bond polyurethane glue, that way all I have to do is
tape balsa sheets together and spread the glue onto the sheets. No need to pre-glue your balsa sheeting here, as the glue expands it will fill in the edges along the sheets and leave very mininal sanding. The cores will be put back into their foam beds and clamped and let sit overnight. The fusealge halves will be joined and I will sheet the inside of the fuselage first, install my bulkheads and cross grain the open bay along the bottom of the fuse. Then I will sheet the outisde. The adhesive I will use is a water based contact adhesive that is available from a couple of sources. It's odorless and give a permanent bond after it dries.
I will post pics as I go along. The techniques are very similar to those that Jack Devine Models uses. They wall work great and create a wonderfully strong but light weight plane that flies great.
Hope you enjoy the pics and i will post more as I go along.
Thanks for looking.
Tom
09-15-2004, 10:18 AM
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RE: GIANT FOAM SPACEWALKER
Looks like a great project.
I built the Spacewalker from RCM plans in the 92 inch size. Your 96 inch wing span will be perfect for a 90 size 4 stroke motor.
Have fun and keep posting those pictures.
I built the Spacewalker from RCM plans in the 92 inch size. Your 96 inch wing span will be perfect for a 90 size 4 stroke motor.
Have fun and keep posting those pictures.
09-27-2004, 06:49 AM
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RE: GIANT FOAM SPACEWALKER
Well, I've finally ahd a chance to complete some more work on my Spacewalker. Here are some pics of the tail section...sheeted, sanded and shaped. I've sheeted the inside of the fuselage, installed two bulk heads, a maple hold down block for the wing. I also mounted the servos for the elevator and rudder in the tail and left access for a hatch cover.
Now we get to sheet the outside of the fuse.
Thanks for looking.
Tom
Now we get to sheet the outside of the fuse.
Thanks for looking.
Tom
09-27-2004, 06:53 AM
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RE: GIANT FOAM SPACEWALKER
Here are some pics now of the fuselage sheeted with the cockpits cut out. I need to do some finish sanding now but I am happy with the way the fuselage turned out. The entire weight of the fuselage is less than 3 1/2 lbs!!!.
Now I am working on the wings and will post pics as they develop.
Thanks again for looking.
Tom
Now I am working on the wings and will post pics as they develop.
Thanks again for looking.
Tom
10-18-2004, 02:45 PM
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RE: GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
Here are some new pics of my project with the fuselage and wings sheeted and assembled. The landing gear is 3/16" aluminum flat stock. The wheel pants are made from balsa. The foam cowl plug is attached and now the next step is to create the cowl from the plug. So far I'm very happy with the way it's turning out, just wish I could spend more time and have it flown already. As it sits it weighs 9 1/2 lbs on 1700 sq in of wing area. My target weight is 15 lbs. If the flight characteristics are good I may offer this as an ARC...I was thinking of making production runs of 10 at a time. Projected power plant is a US 25cc gas engine. Hopefully I'll be able to get some pics next week of the covered airplane and flight testing in the very near future before the Wisconsin snow starts to fly........
Thanks for looking....
Tom
Thanks for looking....
Tom
11-22-2004, 04:51 AM
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RE: GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
Tom,
What a GREAT looking giant. I was wondering what covering you're going to use?? Look forward to seeing more pics!
Shawn
What a GREAT looking giant. I was wondering what covering you're going to use?? Look forward to seeing more pics!Shawn
12-11-2004, 08:46 AM
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RE: GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
Tom,
I'm looking forward to seeing more of your project, and hearing more on the possibility of kits or plans. What you've done so far looks great, can't wait for an update!
Shawn
I'm looking forward to seeing more of your project, and hearing more on the possibility of kits or plans. What you've done so far looks great, can't wait for an update!
Shawn
12-13-2004, 09:26 AM
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RE: GIANT FOAM SPACEWALKER...NEW PICS ADDED 10/18/04
The plane has pretty much just been sitting in the shop. It's all covered. I'm looking at different ideas for the cowl. Other than that, I haven't been able to test fly it yet with the wonderful Wisconsin weather and all. I'll try to post a couple of pictures this week just to show the progress.
I would like to make a single seat version this winter also but I'm currently starting on my next winter project, a 96" span "sport scale" foam AT6 Texan. Target weight is 15 -17 lbs with plug in wings. I'll be using the same techniques as the Spacewalker....foam and balsa cover wings, tail and fuselage. I start a post on that also when i get into the construction farther and can post pics.
Tom
I would like to make a single seat version this winter also but I'm currently starting on my next winter project, a 96" span "sport scale" foam AT6 Texan. Target weight is 15 -17 lbs with plug in wings. I'll be using the same techniques as the Spacewalker....foam and balsa cover wings, tail and fuselage. I start a post on that also when i get into the construction farther and can post pics.
Tom
