STEM GROUP - Event Quick Tip
If you’re looking to pump out a number of plane parts in a short time I have a great solution.
Background:
When I took on a Scout STEM projects to be the main event of the winter Camp-in event, I was excited. I was going to carry forth the fun of Backyard chuck-gliders using Flite Test methods without the frustrations of never getting a good flight before I watched my plane bust, that I had as a kid with the Styrofoam kits.
My victims were Cub scouts ranging from 1st to 5th graders so I couldn’t use Hot Glue. Based on other STEM event feedback I decided on a Tiny Trainer. After wandering around I found a one-sheet TinyTrainer. I test-built one with only packing tape and it worked great! The wing tape holds questionably well, but when rubber-banded on, it flew great.
I was still worried about how much time it would take, but knew it would be worth it. Then I was reminded about the event being the next weekend. With a confirmed 13 sign-ups, that’s when I got worried. That’s where the FT community saved my bacon. In a side comment on the forums, It was suggested I use a scroll saw to solve my problem. The scroll saw suggestion was like someone smacked me on the head, as I thought, "I should've thought of that!" As an amateur woodworker I knew exactly what The-One-Who-Never-Crashes meant.
Tip:
Take 2-8 sheets (mine has a throat for up to 8), and register them to one side. Tape the plans so the pattern starts on the registered side and is centered other-wise. DTFB dimensions vary slightly, so this ensures the pattern stays on the foam through all sheets. Tape them together all around the sides, tight. On one set with 6 sheets I used wide blue painters tape around all sides. The second set of 8 I used masking tape at 4" intervals. The both worked perfectly. Then start your scroll saw and cut to your heart’s content. The foam cuts like a dream of course, just don't push it, let the saw do the cutting. And as always, be safe. Use the appropriate Personal Protective Equipment.
The edges turn out fairly clean and with a quick brushing or blowing loose particles off, you're ready to get those 50% cuts done. If an edge is too wobbly use a sanding block to straighten or smooth it out.
50% score cut prep: Use the scroll saw to notch the ends of the 50% lines. go far enought to notch every layer. Lastly, take a drill and drill out the ends of slots, skewer holes, and cg points. Doing this now saves you looking for the reference lines later... for every individual sheet. If you do this right, the final cutting will just be from notch to notch, and from edge of the slot drill hole to drill hole.
Results:
I used this method to cut 13 Reduced Tiny Trainers in about 1 ½ hrs, with the follow up 50% score cuts taking 1 ½ to 2 more hrs. 3-3 ½” for Thirteen (13) planes.
Final Products:
Sum-up and Take-away:
This method was quick, easy and required no less attenion or time than a normal #11 blade does for 1 plan. Without this approach for mass production I would've been sunk. It's pretty much fool proof. I hope if you need this like I did, This article makes it a breeze.
Here's the main steps and important tips:
- Tape the plan to the top sheet
- Tape little parts with small tape loops to keep the plan attached while you cut.
- Register your plan and DTFB sheets on one side.
- Tape tightly all around and frequently
- Tension your scroll saw blade. (It's foam don't worry.)
- Use a Sanding block for straightness - cut a little wide and sand to the line, (I used my "off" bench sander).
- Notch the ends of the 50% lines.
- Drill the begining and end of slots. and the CG and skewer holes before you take off the plans
With this article in hand you'll be able to cut out "7 in 1 Blow" and save a TON of time, giving you more time to fly!
Plan used: one-sheet TinyTrainer
Scroll Saw:Harbor Frieght Scroll Saw
Special thanks:
The-One-Who-Never-Crashes for the Time saving suggestion!
NerdNic for allowing me to highjack his ManicMicro/nnTigerMoth forum page for a moment.
Last but not least, FliteTest for wild success with your mission by bringing this hobby to everyone who wants it.
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If it was straight foam like depron, sure should.
If a hot wire cuts through the DTFB without a fire, then it should work. It may be slow going as the heat dissipation would be faster through 7 sheet, than 1 and may cool the wire below the cutting point.
Give it a try and let us know.
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