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Adding fairings to trailing edges of the ailerons, elevators and rudder could not be approached in the same manner as previously described. Gluing on 24 feet of fairing pieces that were 3/4 of an inch wide would take too much time and effort. Finally, I figured out a way to make fairings in fifteen inch long strips.
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A Dremel flexible shaft head was mounted on a board at an angle so that a 5/16 OD tungsten ball cutter could be used as a router. The ball height was adjusted until the upper surface was just a little shy of 3/4 of an inch above the board. Before and after fences were mounted to the board so that the cutter would cut just a half ball deep.
The blank strips were fed through the cutter from photo top to bottom while maintaining good contact with the fence. Next the strip was flipped over and fed through again. This makes a groove just below opposite corners. |
After all the blanks were cut and notched, the scroll saw was set up to cut the fairings into their "V" shape. The table was rotated to the 20 degree mark and a fence was installed to help guide the foam blanks through the saw. Two fairings could be cut from each blank.
As one can see, the foam dust sticks to everything. It is a good idea to wear a mask. What would be better is to use a fan suction unit and a filter to draw away all and capture all the dust. |
This is a cross sectional view of the blank as it turns into to a fairing. The blank is on the right. Next to the left is the blank with the 5/16 ID grooves cut, and with cutting lines superimposed. And finally on the far left, the fairings ready to be glued into place. The center section of the blank becomes scrap.
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Three-fourths of an inch thick blue foam was cut into strips one and one-eighth inches wide and about fifteen inches long. I tried to cut a line with a table scroll saw, but I was not good at it. I put a fence on the table, and I was able to cut reasonably straight lines and true surfaces.