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How to Build Lightweight RC Airframes

Flying remote control airplane models can be an enjoyable hobby. But it can also be an expensive one, as planes can cost upwards of $200 for a high-quality model. An alternative for a would-be pilot, who either wants to save money or enhance his enjoyment of the hobby, is to build the plane himself. Crafting a lightweight airframe is a matter of making several decisions, and then putting your do-it-yourself plan into operation.

Things You'll Need

Packaging foam
Hobby knife
Straightedge
Sandpaper, very fine grit
Toothpicks (optional)
Model glue

Instructions

Planning
- 1
  Determine whether you want to follow a plan for your airframe or design your own. There are many plans available that lay out step-by-step creation of an RC plane, including the airframe. Such plans, or build-it-yourself kits, offer the comfort of a tested building method, but decrease the amount of creativity an RC pilot will be able to use.
- 2
  Decide on the style of airplane you wish to build: the style of plane, such as a single-wing or biplane; its size and scale, if you want a realistic model; engine-powered or glider; and the type of remote control parts. The weight of the RC parts may affect your other decisions, as you strive to keep the weight of the airframe down.
- 3
  Choose the lightweight material you wish to build your airframe out of. Popular materials when weight is an issue include balsa wood or packaging foam. Building an airframe out of balsa wood can be quite complex, whereas building one from foam may be simpler for beginners.
Building
- 4
  Sketch out your wing or wings onto a block of foam, and cut it out with a hobby knife. For instance, for a foam airframe with a single-wing design, you can use a hobby knife to carve the wing in one piece. Ensure the wing is rounded in aerodynamic fashion, and in proportion to the fuselage.
- 5
  Sketch out your fuselage, the main body of the airplane, onto another block of foam and carve it out with your knife. Depending on the size of your model, you may need to carve the fuselage out of more than one block. If so, try to make the pieces roughly equal in size and weight, then glue them together with model glue. Make sure the glue is dry before proceeding.
- 6
  Attach the wing to the fuselage with model glue. If the plane is a large one, use toothpicks or small wooden dowels to hold the pieces together while the glue dries. If these are light enough in weight, you may wish to leave them in place for reinforcement.
- 7
  Carve a tail out of another foam block, and attach it following the same method as the wing.
- 8
  Reinforce the wing and tail if necessary with strips of balsa wood, keeping in mind the weight of the model. Sand the foam airframe with very fine-grit sandpaper, along all cut edges or other rough spots.

Aviation