Lost foam fuselages

                    this method is probably the best way to get into using composite materials, its fairly quick to do but each fuselage is a one off. you can make the wings using just a hot wire  and sheet the cores with ply , obeechi or balsa, so a complete plane can be made with just a length of foam cutting wire, and some baisic materials. As long as you cover your foam plug with tape, you can use epoxy or polyester resin, and then melt out the foam with acetone or petrol. Epoxy is stronger, polyester is cheaper and smellier.

I will cover this method in more detail when I use it next, it is not to be underestimated for prototypes and one offs, making a mold is not really viable unless you want five or more parts in my opinion, or you just want to make a mold! It is also an opportunity to use up all those off cuts you have been hoarding up. 

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This site was last updated 02/11/07