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How to Cut Foam Wing Cores

Model aircraft wings were traditionally built from balsa wood. This was a complex and difficult operation, and the wings were easily damaged. Foam wing cores, give a model airplane more lift. The wings are easier to construct and resistant to damage. You can cut your own foam cores to suit the model you wish to construct. Buy a foam cutter or make one yourself to get clean lines without breaking the foam.

Things You'll Need

Expanded polystyrene (EPS) foam for balsa covered wings and EPP for foam wings
Clamps
Marker
Hot foam cutter
Dimensions and pattern for wing cores
Sandpaper

Instructions

- 1
  Download or design your wings. The wingspans are usually 24 to 48 inches, with larger wings providing more lift and stability and smaller wings making the plane more maneuverable. The wings must be airfoil shaped. The leading edge is rounded and wider than the other edge. This provides lift.
- 2
  Clamp the foam to your work surface and trace out your design with a marker. Allow a hot foam cutter to heat to a temperature of 392 degrees Fahrenheit.
- 3
  Guide the foam cutter slowly over the surface of the foam to cut out the wings. Move the cutter firmly and continuously. Leaving the cutter in one place will melt surrounding foam. Perfect your wing design by sanding gently with fine-grade sandpaper. The smoother and more uniform your wings are, the better your plane will fly.

Aviation