Foam Core with lightness built in

7 April 00

This is a short note on the method I was going to use to produce the extended span wings for the Excel Competition, before it crashed.

I will cut a conventional foam core making allowance for the balsa (or veneer) sheeting and will then cut the slots for the spars. I will insert the spars and wing joiners, sheet the leading edge, trailing edge and add the mock rib cap strips. I will finally poke a hole though the panel marked on the drawing below and, using the balsa sheet as a guide, cut out each panels.

The diagram and process are simplified here as each wing panel will have an aileron servo and control surface. I am also thinking about adding flaps to the wing and / or spoilers because of the decreased wing loading.