Low-Cost Foam Cutter

Styrofoam®-core wings have advantages over conventional built-up wings: They can provide a more accurate airfoil and faster assembly times. Presented here is a low-cost jig for cutting your own custom foam wing cores. This cutter features hands-off operation for good results on your very first try. Everything you need to build the foam cutter is available at the local hobby shop, home center, and Radio Shack. With the exception of the power supply, the materials can be purchased for less than $30. Some of the materials you probably already have in your workshop. The aluminum channel may seem odd-sized but it was what we found at the local home center.