SHEETING FOAM WINGS
Revised
4-25-03
Jim Ryan
Introduction: I once swore I'd never resort to foam wings for
my
models; they were built with sticks or not at all. Now, at least 90% of
the
models I build have foam wings. Even as a scratch-builder (which means
I
have to make my own foam cutting templates), foam cores are fast and
easy
to produce, and they make for a quick-building wing that is straight,
strong
and durable. One day when I was slope soaring, I had a midair in which
my
plane and another met leading edge to leading edge. My sloper's
spar-less
partially sheeted foam wing pruned about a foot off the other plane's
built-up
wing and kept right on going. I was convinced.
Foam wings are very versatile, and there are a number of materials
used
for covering them, from balsa or wood veneer at the low-tech end, to
S-glass,
Kevlar and carbon fiber at the high-tech end. Adhesives range from
simple
wood glue to various forms of contact cement to two-sided tape to high
grade
epoxy. Application methods range from simply pressing the skins in
place
by hand to using weights or clamps to hold them down to vacuum-bagging.
Even
the foam itself can range from cheap expanded bead foam to extruded
blue
or gray foam to advanced materials like Rohacell.
Entire books have been devoted to the more advanced processes, and
rightly
so. But the purpose of this article is to outline a method that is
fast, simple,
lightweight and which will give the builder a high chance for success.
For
demonstration purposes, we're using a wing for a small electric model,
so
we won't address details like spars, landing gear mounts etc. that
might be
needed on larger models.
1. Here are the materials needed: For your first wing, I
recommend
using balsa for the skins, since it's easy to work with and all
builders are
used to handling it. You'll need some specialized adhesives: 1) Glue
for
making wing skins; some folks like sandable aliphatic glues like Pica
Gluit,
or you can use thin CA if you're comfortable drawing out long thin
beads
with it. Wood glue has the advantage of requiring a little less
skill
in application technique. 2) Thick odorless CA; this is used for
attaching
the leading edges and tips to the foam cores. 3) Thin odorless CA; this
is
used for gluing the trailing edges of the skins and for applying the
glass
tape to the dihedral joint. 4) Contact cement or laminating/finishing
epoxy
for bonding the skins to the cores. For contact adhesives,
Southern
Sorghum is popular; it's a latex-base adhesive that can be brushed on.
Technical Alert: 3M Super 77 is no longer suitable for use
on
foam wings. The new formulation contains acetone, which will
attack
the foam.
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