Vol Libre n°115 - 1996 - Ulises Alvarez

General instructions to carve fuselages from polystyrene foam

1. Use two polystsyrene foam blocks 30GR/dm3 to form fuselage; cut dimension as close as possible to those indicated in the drawings.

2. Make copies of drawings and cut carefully two side views of fuselage; use vinyl glue to glue them up on each side of the blocks making sure they are correctly located; cut to shape using jig saw, leaving a little margin to finish with fine sandpaper. Glue both blocks with only 3 or 4 drops of vinyl glue.

3. Cut top view of fuselage edge, front and rear of canopy; glue both copies over polystyrene foam already trimed paying attention to wing root section.

4. Jig saw out following former guides; adjust by sanding with 120 sand paper. Draw airfoil wing section, streamline of rib and root..

5. Continue by carving fuselage fuselage sides taking care not cutting over streamline transition shape.

6. Sand streamline rib root by sanding with fine sand paper wrapped and glued over different diameter wood dowels or plastic tubes.

7. Cut out from photocopies templates sections previously glued to cardboard sheets to control fuselage shape; finish external carving of fuselage using templates carefully.

8. Separate both parts of fuselage and hollow with 120 sand paper glureds to fifferent diametezr platic tubes; use motor tool fitted with abrasive bits until reaching thickness of 1.2 to 2.5 mm at front of fuselage.

9. Nozzle components: polystyrene foam, plywood 0.5 mm disc, nozzle block cut of 1mm balsa disc and former of polystyrene, round all components together.

10. After checking carefully that all necessary steps have been taken inside of fuselage, glue both sides of fuselage, gluing front cylinder and nozzle make down block.