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How to Make a Mold for an RC Airplane Wing

Controlled from the ground with a transmitter, radio-controlled model airplanes are easily damaged during hard landings. Airplane wings have a specially shaped leading edge that produces the necessary lift needed to keep the plane aloft. If damaged, the wings must be identically duplicated for the plane to retain its aerodynamic abilities. To properly reproduce a damaged RC airplane wing, a mold must be made from a template of the original wing design.

Things You'll Need

Modeling clay
220-grit sandpaper
Straight edge
Mold releasing agent
Silicone molding compound
Small paintbrush
Petroleum jelly
Plastic food wrap
Dull knife
Fiberglass resin compound
320-grit sandpaper
Paint

Instructions

- 1
  Retrieve as many pieces of the original wings as possible. Create a wing template by piecing the parts of the wing back together and filling in any holes and gaps with modeling clay. Allow the clay to dry completely.
- 2
  Smooth the surface of the wing template, including spots where clay meets the fiberglass, with 220-grit sandpaper. Run a straight edge along all surface areas of the template to ensure uniformity, sanding any anomalies as needed.
- 3
  Coat the wing template with mold releasing agent. Cover the bottom of a shallow pan with 2 inches of silicone molding compound. Carefully lay the wing template on the surface of the molding compound. Gently push the template into the compound with your fingers until the depth of the wing is submerged halfway into the compound. Allow the compound to cure according to the manufactures instructions.
- 4
  Apply a layer of petroleum jelly over the top of the wing template and cured molding compound with a small paintbrush.
- 5
  Lay a piece of plastic food wrap over the wing and molding compound and gently smooth the film into the petroleum jelly, working out any air bubbles with your fingers.
- 6
  Cover the top of the template completely with molding compound and allow the compound to cure.
- 7
  Work the cured mold from the pan, using the edge of a dull knife if needed. Pull the mold sections apart with your hands and carefully work the template from the mold.
- 8
  Coat the interior of the mold with mold release compound and fill the top and bottom sections on the mold with fiberglass resin. Place the top section of the mold over the bottom section and allow the resin to cure according to the product directions.
- 9
  Separate the mold sections and carefully bend the silicone free of the new wing. Sand the wing with 320-grit sandpaper and paint as desired.

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