Laying out foamwing cut outs
 

I have 2 48" wing pannels. They are sheeted foam, and are straight.
I need to make four cut outs, one ea. for aileron servos and one ea. for flaps.

Was considering using the rip fence on my table saw with a dato blade and cutting a trough to lay both wires in. Then filling the trough with a balsa strip for filler and sanding flush. I would hot wire cut the drop ins for the servos and use plywood plates glued to the skin for hard points. Any one have any better ideas?

Dremel tool w/ router attachment
 

You could use a Dremel tool with a router attachment. That way, you can see what you are cutting. Just set up a straight edge to keep the lines straight. Use a template for the servo cutout.

Then fill as described above.

Laying out foamwing cut outs
 

The Dremel tool with a router attachment is the way to go. Just make some thin plywood templates and place them where you need the cutout, set the depth and get after it. You can melt the passages in the foam wing with a heated piece of 1/4" piano wire. If you route the channels for the servo wires you will have to cap them off with something.

Forgot to add, when you do this wear a respirator, eye protection, and keep a vacuum handy for frequent clean up's, as this really makes a mess.

Vince

Laying out cuts in wimg
 

Thanks guys, I like your ideas better than mine

Laying out foamwing cut outs
 

You can also cut a nice slot with an exacto blade, remove the balsa sheeting from the slot, and then melt a well for the wire with a soldering iron. If you do it right, the sheeting will go right back in place after you install the wires.

Laying out foamwing cut outs
 

As stated above, I have used the soldering gun and wire method, with good results.

Vince

I like MinnFlyer's idea....
 

....cut in a "Vee" slot, about 1/2 in. wide, and 1/2
deep, with a new exacto blade. Burn a small trench
at the bottom with the soldering iron. Glue the piece
right back in.

If you ever had to replace the servo ( heaven forbid ),
you could re-cut the same slot, say 3/4 wide, and 3/4
or so deep....and repeat the process. ;)

Dave. :)

Cutting Foam Wing
 

Hey Dave, That's a slick idea!
Bruce

Laying out foamwing cut outs
 

When you epoxy the strip back in ( 5-min ) use
some small blocks to hold it dead flat on the wing,
wax-paper between. As soon as it grabs, wipe the
remaining epoxy with a rag on your finger....with
rubbing alcohol, nice and clean, and flat. :D

It's ready to cover....no sanding, no muss, no fuss.
All in one step.... ;)

Dave. :)

Laying out foamwing cut outs
 

For Servo boxes, I use the dremel with router attachment. This makes very smooth cuts.

For Servo wire tubes, I bore through the foam with a sharpened brass tube (1/2") using a jig to keep the channel straight.

Albert

Laying out foamwing cut outs
 

for servo wire leads:

if you are a hunter or know someone who shoots archery then bumb, borrow or steal :D an arrow with a target / field point. we heat the point with a torch and then just push it into and through the foam to your servo bay. of course the tricky part is laying out where to make the tunnel and shooting the arrow in a straight line (I know, poor attempt at humor)

this makes a nice clean tunnel to run your wires

Hubb