BowFLEx FOAM Graphic Design Jill Ann Cavanaugh CUTTER UT Michael Jennings THE DEVELOPMENT use foam wings began years ago Still typically few modelers club have equipment ability cut foam wings Building foam wing warp very difficult foam wings essentially straight Thus model will fly increased predictability Building multiple foam wings same airfoil becomes easy takes less time built-up wings article describes easy build economical efficient power supply nichrome wire bow cutting foam primary use foam cutter cut wings Radio Control Control Line models fuselage parts person basic building skills can build nichrome wire bow about $30 Safety Precautions modeler should have use Ground Fault Circuit Interrupter GFCI device GFCI connects between wall outlet electrical tool reduce risk electrocution Current electrical codes require GFCI outlets bathrooms kitchens cutters GECI 2 x 4 electrical box short electrical wire male plug July1998 49 rigid end bow power supply Ground Fault Circuit Interrupter GFCI essential cut foam wings safely power supply components mounted Power supply components temporarily connected prior mounting metal boxin metal box Box lid removed see transformer has isolated secondary output 24 voltsthe arrangement components second safety device isolated transformer type transformer separates primary electrical input secondary electrical output Cutting foam wing two-person jobone person end bow will provide increased safety greater control cutting foam block Connect isolated transformer secondary 24 volts Refer enclosed transformer literature proper wire combination get 24 volts Note isolating taping two additional secondary voltage wires prevent shorting Connect electrical components before installing system Drill mount dimmer switch metal box well isolated transformer Romex electrical clamp Connect wiring including three-amp fuse fuse holder Removal mounted components may required connection power cord eight feet two-conductor electrical wire bow electrical supply also eight feet twoconductor electrical wire exit metal box through Romex electrical clamp compact assembly Bow Fabrication Any wood glue acceptable such Elmers Professional Carpenters Wood Glue An epoxy adhesive also acceptable Coat mating parts glue prior fastening together screws added rigidity Bow construction starts laminating two yardsticks Put coat glue over surfaces weight down flat surface allow dry Make two laminates After drying glue another yardstick laminate make T crosssection beam second laminate cut length 12 inches rigid arm second length 121/2 inches pivoting arm Make pair six-inch right triangles /s MasoniteTM /s plywood Assemble rigid corner bow pivoting end bow make pair 2 x 6-inch rectangles /s MasoniteTM plywood Taper pair end professional look Attach glue screw T beam pair should 50 Model Aviation saw cut through end lug pivot end bow cut allows building hollow-core foam wings Elizabeth Jennings bow power supply foam block Total cost nichrome-wire bow power supply approximately $30 pivot pivot end bow tension spring should have light tension retracted position extend past end T beam 1 inches second laminated 12-inch yardstick pivoting arm Locate pivot bolt 3/ inch end MasoniteTM centered other direction Slip laminated yardstick between pair center yardstick 3A inch end MasoniteTM Drill pivot hole bolt assembly together Install tension spring light tension retracted position Fabricate pair 3/ x 2 end lugs Scrap /16 steel brass acceptable material Drill /32 diameter hole end lugs four holes end lugs make saw cut 3A2 diameter hole necessary cutting hollowcore wings such used Control Line wire must fished through foam core reconnected end lug Bend metal L shape 1 X /2 saw cut short leg L Screw saw-cut L pivoting end bow Screw other lug rigid end bow Thread nichrome wire through A6 wheel collar rigid end bow pivoting end bow Attach second wheel collar end wire wire will slip through saw cut pivot end will held wheel collar rigid end bow pull nichrome wire until pivot end center its travel Slip wheel collar place tighten set screw Roll up excess nichrome wire rigid end bow A6 collar large side secure wire short piece filler wire inserted through collar firmly secure nichrome wire Drill Vs diameter holes approximate five-inch centers down center yardstick laminate Weave single conductor through yardstick laminate allowing four-inch electrical conductor excess end Attach alligator clips end electrical conductor Connect alligator clips nichrome wire approximately center rigid end bow cut single conductor attach pigtail end connectors will mate bow electrical supply Test bow scrap foam prior cutting wing takes some practice adjusting dimmer switch get proper wire temperature Maintain nichrome wire lowest temperature cut foam block wire glows red too hot wire should cut through foam kerf width cut about 1 s width nichrome wire Remember nichrome wire gets very hot can easily cause serious burn rials 110-volt isolated transformer Five-foot length nichrome wire 110-volt light dimmer switch Three-amp fuse fuseholder Two eight-foot lengths two-conductor electrical wire Eight feet single-conductor electrical wire Two alligator clips Associated electrical connectors Romex electrical clamp 4 x 4 x 4-inch metal box x 8-inch spring Five yardsticks Scrap MasoniteTM /8 plywood Associated panhead screws x bolt nut washers Associated /s screws nuts Sources Elmers Professional Carpenters Wood Glue Borden Inc Dept CP Columbus OH 43215 Isolated transformer Model 1TR402 cost $1395 Interstate Electric Mfg Nichrome wire Sig Manufacturing Co Inc 401 South Front St Montezuma IA 50171 July 1998 51 T Michael Jennings 604 Banbury Rd Knoxville TN 37922
Edition: Model Aviation - 1998/07
Page Numbers: 49, 50, 51
Edition: Model Aviation - 1998/07
Page Numbers: 49, 50, 51
BowFLEx FOAM Graphic Design Jill Ann Cavanaugh CUTTER UT Michael Jennings THE DEVELOPMENT use foam wings began years ago Still typically few modelers club have equipment ability cut foam wings Building foam wing warp very difficult foam wings essentially straight Thus model will fly increased predictability Building multiple foam wings same airfoil becomes easy takes less time built-up wings article describes easy build economical efficient power supply nichrome wire bow cutting foam primary use foam cutter cut wings Radio Control Control Line models fuselage parts person basic building skills can build nichrome wire bow about $30 Safety Precautions modeler should have use Ground Fault Circuit Interrupter GFCI device GFCI connects between wall outlet electrical tool reduce risk electrocution Current electrical codes require GFCI outlets bathrooms kitchens cutters GECI 2 x 4 electrical box short electrical wire male plug July1998 49 rigid end bow power supply Ground Fault Circuit Interrupter GFCI essential cut foam wings safely power supply components mounted Power supply components temporarily connected prior mounting metal boxin metal box Box lid removed see transformer has isolated secondary output 24 voltsthe arrangement components second safety device isolated transformer type transformer separates primary electrical input secondary electrical output Cutting foam wing two-person jobone person end bow will provide increased safety greater control cutting foam block Connect isolated transformer secondary 24 volts Refer enclosed transformer literature proper wire combination get 24 volts Note isolating taping two additional secondary voltage wires prevent shorting Connect electrical components before installing system Drill mount dimmer switch metal box well isolated transformer Romex electrical clamp Connect wiring including three-amp fuse fuse holder Removal mounted components may required connection power cord eight feet two-conductor electrical wire bow electrical supply also eight feet twoconductor electrical wire exit metal box through Romex electrical clamp compact assembly Bow Fabrication Any wood glue acceptable such Elmers Professional Carpenters Wood Glue An epoxy adhesive also acceptable Coat mating parts glue prior fastening together screws added rigidity Bow construction starts laminating two yardsticks Put coat glue over surfaces weight down flat surface allow dry Make two laminates After drying glue another yardstick laminate make T crosssection beam second laminate cut length 12 inches rigid arm second length 121/2 inches pivoting arm Make pair six-inch right triangles /s MasoniteTM /s plywood Assemble rigid corner bow pivoting end bow make pair 2 x 6-inch rectangles /s MasoniteTM plywood Taper pair end professional look Attach glue screw T beam pair should 50 Model Aviation saw cut through end lug pivot end bow cut allows building hollow-core foam wings Elizabeth Jennings bow power supply foam block Total cost nichrome-wire bow power supply approximately $30 pivot pivot end bow tension spring should have light tension retracted position extend past end T beam 1 inches second laminated 12-inch yardstick pivoting arm Locate pivot bolt 3/ inch end MasoniteTM centered other direction Slip laminated yardstick between pair center yardstick 3A inch end MasoniteTM Drill pivot hole bolt assembly together Install tension spring light tension retracted position Fabricate pair 3/ x 2 end lugs Scrap /16 steel brass acceptable material Drill /32 diameter hole end lugs four holes end lugs make saw cut 3A2 diameter hole necessary cutting hollowcore wings such used Control Line wire must fished through foam core reconnected end lug Bend metal L shape 1 X /2 saw cut short leg L Screw saw-cut L pivoting end bow Screw other lug rigid end bow Thread nichrome wire through A6 wheel collar rigid end bow pivoting end bow Attach second wheel collar end wire wire will slip through saw cut pivot end will held wheel collar rigid end bow pull nichrome wire until pivot end center its travel Slip wheel collar place tighten set screw Roll up excess nichrome wire rigid end bow A6 collar large side secure wire short piece filler wire inserted through collar firmly secure nichrome wire Drill Vs diameter holes approximate five-inch centers down center yardstick laminate Weave single conductor through yardstick laminate allowing four-inch electrical conductor excess end Attach alligator clips end electrical conductor Connect alligator clips nichrome wire approximately center rigid end bow cut single conductor attach pigtail end connectors will mate bow electrical supply Test bow scrap foam prior cutting wing takes some practice adjusting dimmer switch get proper wire temperature Maintain nichrome wire lowest temperature cut foam block wire glows red too hot wire should cut through foam kerf width cut about 1 s width nichrome wire Remember nichrome wire gets very hot can easily cause serious burn rials 110-volt isolated transformer Five-foot length nichrome wire 110-volt light dimmer switch Three-amp fuse fuseholder Two eight-foot lengths two-conductor electrical wire Eight feet single-conductor electrical wire Two alligator clips Associated electrical connectors Romex electrical clamp 4 x 4 x 4-inch metal box x 8-inch spring Five yardsticks Scrap MasoniteTM /8 plywood Associated panhead screws x bolt nut washers Associated /s screws nuts Sources Elmers Professional Carpenters Wood Glue Borden Inc Dept CP Columbus OH 43215 Isolated transformer Model 1TR402 cost $1395 Interstate Electric Mfg Nichrome wire Sig Manufacturing Co Inc 401 South Front St Montezuma IA 50171 July 1998 51 T Michael Jennings 604 Banbury Rd Knoxville TN 37922
Edition: Model Aviation - 1998/07
Page Numbers: 49, 50, 51
BowFLEx FOAM Graphic Design Jill Ann Cavanaugh CUTTER UT Michael Jennings THE DEVELOPMENT use foam wings began years ago Still typically few modelers club have equipment ability cut foam wings Building foam wing warp very difficult foam wings essentially straight Thus model will fly increased predictability Building multiple foam wings same airfoil becomes easy takes less time built-up wings article describes easy build economical efficient power supply nichrome wire bow cutting foam primary use foam cutter cut wings Radio Control Control Line models fuselage parts person basic building skills can build nichrome wire bow about $30 Safety Precautions modeler should have use Ground Fault Circuit Interrupter GFCI device GFCI connects between wall outlet electrical tool reduce risk electrocution Current electrical codes require GFCI outlets bathrooms kitchens cutters GECI 2 x 4 electrical box short electrical wire male plug July1998 49 rigid end bow power supply Ground Fault Circuit Interrupter GFCI essential cut foam wings safely power supply components mounted Power supply components temporarily connected prior mounting metal boxin metal box Box lid removed see transformer has isolated secondary output 24 voltsthe arrangement components second safety device isolated transformer type transformer separates primary electrical input secondary electrical output Cutting foam wing two-person jobone person end bow will provide increased safety greater control cutting foam block Connect isolated transformer secondary 24 volts Refer enclosed transformer literature proper wire combination get 24 volts Note isolating taping two additional secondary voltage wires prevent shorting Connect electrical components before installing system Drill mount dimmer switch metal box well isolated transformer Romex electrical clamp Connect wiring including three-amp fuse fuse holder Removal mounted components may required connection power cord eight feet two-conductor electrical wire bow electrical supply also eight feet twoconductor electrical wire exit metal box through Romex electrical clamp compact assembly Bow Fabrication Any wood glue acceptable such Elmers Professional Carpenters Wood Glue An epoxy adhesive also acceptable Coat mating parts glue prior fastening together screws added rigidity Bow construction starts laminating two yardsticks Put coat glue over surfaces weight down flat surface allow dry Make two laminates After drying glue another yardstick laminate make T crosssection beam second laminate cut length 12 inches rigid arm second length 121/2 inches pivoting arm Make pair six-inch right triangles /s MasoniteTM /s plywood Assemble rigid corner bow pivoting end bow make pair 2 x 6-inch rectangles /s MasoniteTM plywood Taper pair end professional look Attach glue screw T beam pair should 50 Model Aviation saw cut through end lug pivot end bow cut allows building hollow-core foam wings Elizabeth Jennings bow power supply foam block Total cost nichrome-wire bow power supply approximately $30 pivot pivot end bow tension spring should have light tension retracted position extend past end T beam 1 inches second laminated 12-inch yardstick pivoting arm Locate pivot bolt 3/ inch end MasoniteTM centered other direction Slip laminated yardstick between pair center yardstick 3A inch end MasoniteTM Drill pivot hole bolt assembly together Install tension spring light tension retracted position Fabricate pair 3/ x 2 end lugs Scrap /16 steel brass acceptable material Drill /32 diameter hole end lugs four holes end lugs make saw cut 3A2 diameter hole necessary cutting hollowcore wings such used Control Line wire must fished through foam core reconnected end lug Bend metal L shape 1 X /2 saw cut short leg L Screw saw-cut L pivoting end bow Screw other lug rigid end bow Thread nichrome wire through A6 wheel collar rigid end bow pivoting end bow Attach second wheel collar end wire wire will slip through saw cut pivot end will held wheel collar rigid end bow pull nichrome wire until pivot end center its travel Slip wheel collar place tighten set screw Roll up excess nichrome wire rigid end bow A6 collar large side secure wire short piece filler wire inserted through collar firmly secure nichrome wire Drill Vs diameter holes approximate five-inch centers down center yardstick laminate Weave single conductor through yardstick laminate allowing four-inch electrical conductor excess end Attach alligator clips end electrical conductor Connect alligator clips nichrome wire approximately center rigid end bow cut single conductor attach pigtail end connectors will mate bow electrical supply Test bow scrap foam prior cutting wing takes some practice adjusting dimmer switch get proper wire temperature Maintain nichrome wire lowest temperature cut foam block wire glows red too hot wire should cut through foam kerf width cut about 1 s width nichrome wire Remember nichrome wire gets very hot can easily cause serious burn rials 110-volt isolated transformer Five-foot length nichrome wire 110-volt light dimmer switch Three-amp fuse fuseholder Two eight-foot lengths two-conductor electrical wire Eight feet single-conductor electrical wire Two alligator clips Associated electrical connectors Romex electrical clamp 4 x 4 x 4-inch metal box x 8-inch spring Five yardsticks Scrap MasoniteTM /8 plywood Associated panhead screws x bolt nut washers Associated /s screws nuts Sources Elmers Professional Carpenters Wood Glue Borden Inc Dept CP Columbus OH 43215 Isolated transformer Model 1TR402 cost $1395 Interstate Electric Mfg Nichrome wire Sig Manufacturing Co Inc 401 South Front St Montezuma IA 50171 July 1998 51 T Michael Jennings 604 Banbury Rd Knoxville TN 37922
