One great thing about building with dollar store foam is you can attempt things you just will not do with an expensive plane. I will crash them, laugh, break out the hot glue and go again. Once it's no longer flight worthy, break out the template, and do it all again.
One thing that seems to never outlast the planes is the power pod. Changing them in and out of planes, crashes, and rough landings take their toll. I figured, since this one pod is meant to fly multiple planes over and over again, it should be stronger than the planes themselves. I decided to reinforce them.
I happened upon a piece of 3/16 ply that was getting tossed at work. I have used this thickness with great success as firewalls since I started building and figured a 1x4 foot section would make plenty. Unfortunately, I noticed later that the layers were coming apart and the individual layers would not be strong enough by themselves to make a firewall or even control horns.
I did decide to use those layers to bolster my pods. The weak points being right behind the firewall where it will crumple or separate. The other being where the skewer holds it into the plane. After a bit of use the hole widens, even with a couple of layers of tape.
I glued two pieces to either side of the pod prior to gluing the firewall. This supports the foam cheeks from collapse and strengthens the joint to keep the firewall from pulling away. I tape it as usual after this addition.I also drill out the landing gear holes with a 3/32 drill bit which is the same size as the skewers I use. I push them through with the pointed end a few times after which the blunted end can fit through with just enough room.
One other place I used these layers was at the skewer holes. I cut some cm square bits and hot glued them in place over each rear hole.
I drilled each one as before and the skewer stays in nice and tight and any pulling from the zip ties or just shifting slightly in the plane is absorbed by the wood instead of the foam. This can be done with the same hobby grade plywood as the firewall and control horns, if you are fortunate enough to be able to find it.
The one I made in this manner prior to this one is holding up fine through plenty of use and there is no noticeable weight issues. That and I don't find myself having to come in anymore with a non-working pod, which can kill an afternoon.
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The key here is surface area ALL the pressure on these skewers is pusing down on a few lil millimeters of foam. It is only a matter of time until they elongate and need repair.
Here's what I do: Popsicle sticks. You can buy approximately a jillion for $1.00. Or, even more pennywise, you get them free with delicious popsicles! Cut them into li'l 1 inch (or 2, or 3 - Whatever makes you happiest) lengths. You can drill a skewer-sized hole in them, but that is overkill (They only get pulled down). I cut a 'V' notch in them with an exact-o knife (You can also sand/dremel/chew/burn/etc. a notch. Reinstall the skwere and hot or polyurethane glue that (former) sucker to the fuselage, so it cradles the skewer.
NOW, instead of a measly millimtere of foam holding the skewer at bay, you may have almost a half-square-inch of surface area! Huzzah! It adds a ridiculously small amount of weight, and provides an equally ridiculous amount of strength!
I hope this helps!
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Oh, I have previously picked up and will be using for the reinforcements, found pre-cut squares and rectangles 1/16" plywood at Michaels Craft Store. They come in packs with assorted sizes in squares, rectangles and I think circles as well. Very convenient for reinforcement or mounting plates in scratch builds.
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I take tape and a glue gun to the field with me, so I can effect running repairs if necessary. My electronics has had some nasty point-first crashes, but it's still all working OK.
Flitetest crew: any thoughts about the best tradeoff?
tim
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it adds very little weight to power pod,but adds three times the strength!
I know from a full-on power dive into the street,crushed the motor but no damage to the power pod itself!
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