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How to Make Your Own RC Polystyrene Wing

Flying wings are delta-shaped airfoils that fly without the remainder of a conventional model plane -- they are only wings. Many wing pilots like the challenge of flying without all of the "extras" found on a conventional plane. In many cases, wing pilots fly without power, relying on ridge currents and updrafts to keep their wings in the air. You can build your own powered or unpowered wing by finding a design plan on the Internet and using inexpensive materials such as foam and plywood, providing you with a simple and inexpensive model that's lightweight and durable.

Things You'll Need

Wing plans
1/4-inch foam
Hobby knife
Remote control radio and receiver
Mini servo motors
Electric motor and propeller
Electronic speed control
Plywood rods
Control rods and control horns
Velcro tape
Packing tape
Clear epoxy

Instructions

- 1
  Clear a workspace and lay out the plans for your wing. Transfer the design of the wing onto the foam sheet.
- 2
  Cut the wing pattern from the foam sheet using the transferred design as a template. Set aside the excess foam. Using the plans as a guide, score the foam sheet and fold the top 1/3 over to form a triangular shape. Cut lengths of plywood and glue them to the leading edge of the folds so that when you are done the wood is inside the fold.
- 3
  Score the bottom edge of the wing, ignoring the middle 1/3 of the wing, to make elevons. Cut the elevons. Apply tape to the cut edges. Slide them together and use more tape to create a hinge. Install control horns on each elevon.
- 4
  Glue the remaining foam to the wing to create two vertical stabilizers for your wing. Glue them to the outside edges of the wing. Mount the engine on a piece of plywood and glue it to the rear of the wing, pusher style. Cut two small rectangles in the folded section of the wing and install the mini servos for the elevons. Secure them in place with Velcro or double-sided foam tape. Make two small holes to run the wires to connect the servos to the receiver.
- 5
  Install the receiver, battery and speed controller. Mount them in a line along the center of the wing, securing them with Velcro or double-sided tape. If you have leftover foam, you can use it to make a nose cone for the wing and a cover for the electronics. Use the packing tape to reinforce the nose and leading edges of the wing. Attach the control rods. Glue a piece of wood to the bottom of the wing to serve as a handhold for launch and as a landing skid.
- 6
  Power up your model and test the throttle and control surfaces. Make sure it is properly balanced.

Aviation