Aug 1, 2011

Foam Wing - Full Fused Plane

While visiting in Minnesota, my brother-in-law and I built a few airplanes.  He bought 1 inch foam insulation at the local hardware store, which we fashioned into wings with real airfoils.  Using 1/4" foam, I've made many wings with under-camber, but never made a wing with a true airfoil that produces lift.

We didn't go to the trouble of making a hot wire, we simply cut the wing to shape with a razor blade, and then ran it through the table saw on the leading and trailing edge to start the airfoil shape.  We then sanded the wings with foot long wooden sanding blocks and coarse sanding paper.  Starting with 60 grit, we worked our way down to 150 grit, and very quickly had near perfect wing cores.

Here are a few pictures of my plane with the finished wing.  The plane itself is constructed of 1/4" foam, with a  2" block of foam sandwiched into the nose area, giving structural rigidity as well as a place to mount the battery, esc, servos and motor.  There is no wing spar on this plane, the foam provides enough structural support, but spare carbon fiber wouldn't hurt.

Overall its a fun project, but as always, try to keep the weight down or it won't fly very satisfactorily.   This plane weighed in at a little over a pound with the battery.

Turnigy 2217 20turn 860kv 22A Outrunner
1 - 2200 mah 3 Cell LiPo
4 - HXT900 Servos
1 - HobbyKing 30A BlueSeries Brushless Speed Con
1 - TP Slow Fly propeller 11x4.7
1 - 6 channel spectrum compatible rx  


  1. Thanks very much for this post. I am just returning to aeromodelling after many years and want to build a foam version of the Junior 60, electric powered. You have got me on my way.

    1. Glad your getting back into the hobby, it has certainly been changing rapidly, but I believe all for the better... It's becoming more affordable, and the radio capabilities are incredible. Stay tuned, I have several posts for the new year;) I've been a bit back logged...