Couple of possible improvements: 1) Put down cling wrap on table to aid cleanup. 2) Maybe embed servos and electronics in wing before foaming or using cling wrapped blocks to make exact voids in foam for electronics. All that being said, great process, great results. Well done.
I love the building of the models from scratch, so fulfilling. any method that shortens time, is a plus, 1st lesson I had to learn the hard waay was, not strong but "just strong enough" or they disintegrate on impact
Always wanted to experiment with expanding foam to make a wing. It always seemed so durable and like a great way to make a custom airfoil. Since it's so heavy I never gave it a shot. I never thought about making a slope glider...the weight is perfect to cut through heavy winds. Great demonstration of how it can be done!
if you use expanding foam regularly you would probably find it cheaper to get a foam gun or a foam gun kit same as at screwfix . you can dial it down to a 5mm bead or out to 50mm plus and it won't go off in the tin like a lot of the one shot tins , you also get gun cleaner and heat resistant foam .
Lots of comments have been made that a hot wired wing would be just as good. IkyAlvin's method creates a molded stressed skin wing that is extremely strong and still pretty light. It also has some impact tolerance. In order to replicate the strength with a hot wired core it would need a fiberglass or wood skin added to it. That would result in a very strong but fragile wing. Slope planes lead a hard life so some resilience to impact is a good thing. Once the mold has been made many identical wing panels are easily created.
Absolutely brilliant!! I was thinking about using expanding foam also, but you beet me to it..... My idea was not nearly as elaborate and after seeing this, probably would not have worked anyway. If I ever get around to construction, I will definitely put your good ideas to use. Thank you!
I've used a similar process. Try this: make a thin balsa sheet, wet it, then put a carbon tube where you want the thickest part of the airfoil and wrap the now flexible balsa around it. CA glue the trailing edge, then fill with foam. Trim ends and you have a massively strong structure with no mold needed. Then, either use low-temperature heat shrink covering, or seal and paint. I've used this technique since 2002 and have had zero problems with it.
I used expanding polyurethane foam from a can to prevent strong winds lifting corrugated steel sheet on my workshop roof . (This had been laid over a flat felt roof which had begun to feel its age and started to leak). A one-second squirt into each of the raised metal corrugations. Worked fine, the wind did not lift the panels any more, but the foam just kept on expanding at a very slow rate for about a year until it was stable. Concerned that a wing section may change unless kept in a jig for a long time to stabilise.
looks like a nice alternative to using a hotwire, one day i might have to experiment using mylar sheets as a releasing agent so im left with just the foam core and so that i can vacuum bag fiberglass directly to it. thanks for shareing
I think it would have been better to use mix your own foam and have the mould on end then pore in the foam from the top it is easy to add to if you think you have not mixed enough and then just pore the extra in, I have used it for several projects I even repaired my rudder on my 40 foot sail boat after it split open by cleaning it out and taping up the rear then added the foam from the top I just watched it expand then when the expansion was slowing down just mixed more and added it this i did 4 times until it was full then re fibre glassed the back end and top and it was stronger than when it was new, I also built a new freezer using plastic board and filled the outside with it it ended up having around 6-8 inches on the base and 4-6 inches on the sides and top it would then freeze in less than 1/2 the time it use to take even though it was the same motor, pump and freezer plates it would pay for its self in the first year in using less power to run the pump than it use to also the pump came on less than half as often compared to what it use to which with it taking half as long to get the temp down and operating less than half as often it was actually only running 1/4 of the time it use to.
For a foam wing, this technique is more labor intensive, time consuming, and complicated than just hot wiring. And it also exposes one to chemicals, needlessly. IMP, it's a step backwards.
I've had great success with expanding foam and cling film! The cling film seems to bond with the expanding foam to make a really strong hard coating, a bit bumpy but awesomely quick for lids/housings etc. Would work well with a mould I'm sure. I lay out the cling film spray foam on, mix it to remove air (and make a denser hard outer layer) then spray foam on top and add a top layer of cling film(with mixed foam as before). It's proper crash proof!
hey, I've been flying remote control planes, mostly gliders since I was about 14 years old and you did a great job on that man it flew obviously with most of the stuff we build from the ground up it's going to take a little bit of refining but damn good job sir
Audio narrative would complement the visual... Music is not needed, but a little background music might help when there is nothing else to say, so to speak... Nice job!
How strong are these wings compared to EPP? I can make airfoil with 9mm EPP very quickly and by using carbon fiber tubes or fishing pole sections, they become indestructible and still very light.
Try Locktite titefoam. it's more flexible and has a smaller, tighter foam structure. no large pockets of air that could weaken the structure of the wing
Very good idea. It takes more work, but here you will get smooth surface instantly compared to hot wire. This is more suitable method for larger projects. Keep your good work :)
Good job, but he's not really making a wing from expanding foam. He's eliminating the need for internal gussets and profiles for the Selitac folded wing.
Spot on. That is exactly what I'm doing. The foam strength and any voids are not really important as the skin is stressed. The foam fill keeps the skins apart and helps control the compression failure of the upper surface. Just like the common I beam.
I use this foam a lot for work and they do a gun specifically for it which is a lot more controllable and you would have a lot less expanding out of the mould. And you can re use it which is a bonus too 👍🏻 nice idea and a good result though
Nice, everything about this is very good. Flying the finished beast looks like a very tough challenge though with no fuselage or tail for directional perspective! I'd lose it in 6 seconds. This guy is pretty darn good! A1.
I am working on something like that and it seems lots of work was put it into creation of that wooden box. Is there an easier way to make the foam pressed like that?
I think there are lots of things you could try. A simple method might be to try making something out of foam that looked like the discarded top and bottom halves of a hot wire cut wing. Another interesting thing to try would be to use expanding foam to make an outside mould of an existing wing. Cling wrap/film can be used to stop the expanding foam sticking. The wooden frame may not be totally necessary but it keeps the mould straight and protects it. Why not make it in such a way that it can be reused? There are plenty of examples on CZcams of expanding foam destroying carefully crafted model boats - so bear in mind it can be powerful stuff. The most important aspect is that the moulded item is fully supported by the mould in all areas where the shape is important. The fit/alignment of the mound at the trailing edge is quite important. In later versions of the wing I have chamfered underlay at the join to get a thinner trailing edge. Good luck - make a video and let me know how you get on.
If you already have something to copy or can make a mock up some how you could use this technique.. Paint on silicon rubber that hardens into the mold. Then before removing from the object you molded, you coat the outside of the rubber with fiberglass to make the hard outer case to support the rubber mold. You coat the rubber mold with a chemical release agent, then put in the expanding foam. Then you have a mold that can be reused many times. www.smoothon.hu/antler%20reproduction.pdf
Very interesting. I have some canned foam somewhere. I reckon that if you could extend the nozzle on the can, you could make a much bigger wing, 8ft or even more! B¬)
Great idea, must do some experiments to see if there is enough flexibility and compressibility in the foam if you want to build longer wings or in case of crash so the frame would not fracture
Nice idea, but when you only show text and pictures, you can also write a blog. Its way easyer and nobody expects to be entertained by a video with sound and speech. ;)
I need about 5 minutes for one 50 to 70cm piece of wing, from cutting the foam from the big piece, putting on the templates and cutting lower and upper side. Plus: the excess material is a good way to store the wings. They actually pile up on the shelve behind me.
The sturdy skin would seem to be an advantage and would obviate need for shucks. And the idea is to re-use the mold. Maybe you can cut perfect LEs with a hot wire, but this method pretty much guarantees it.
Es hermoso, es espectacular, es una maravilla, es grandioso el lugar donde vuela! Del ala lo unico que rescato es su construccion creativa y varata. Muy varata.
good idea of great video but an awful lot of work for something that cost peanuts to start with, really have to ask a question is it worth all the messing about?
very nice idea, very nice video, and flying not sure win but i will try your method. it does look like a lot of work for a wing but if you plan far enough ahead you could use the same Mould for several airplanes. great job and thank you for sharing
Interesting method of producing foam wings. However,it does not appear to have any advantage over the traditional hot wire cut foam method. Probably more expensive, messy and time consuming. In my opinion your method has potential but needs more refinement. May I encourage you to continue, you may start a wing making revolution!
Closed cell or open cell.. neat I would mold the fuel tanks in each wing you can carry triple fuel hmm damn they might say the boy is genius except. Thus is just pulling idea how the big boys did it that's all.. I would put battrys in wings to. Cameras lights . The options so cool I'm buildings a plane now.. thanks thanks rhanks
Couple of possible improvements:
1) Put down cling wrap on table to aid cleanup.
2) Maybe embed servos and electronics in wing before foaming or using cling wrapped blocks to make exact voids in foam for electronics.
All that being said, great process, great results.
Well done.
I had this idea a few years back but never followed through glad to see some else did AND did it! Nice job
Sweet idea. Always cool to see people build something themselves versus buying it at a store.
I love the building of the models from scratch, so fulfilling. any method that shortens time, is a plus, 1st lesson I had to learn the hard waay was, not strong but "just strong enough" or they disintegrate on impact
I watched this for the dialogue. Best I've heard on YT
The Banter is especially nice. 😋
This dude would not shut up.
Profoundly witty commentary!
Always wanted to experiment with expanding foam to make a wing. It always seemed so durable and like a great way to make a custom airfoil. Since it's so heavy I never gave it a shot. I never thought about making a slope glider...the weight is perfect to cut through heavy winds.
Great demonstration of how it can be done!
yes, indeed it's very heavy but very durable.
Good on you for trying something different, thinking differently, it gives you a nice smooth surface immediately, not a bad idea.
if you use expanding foam regularly you would probably find it cheaper to get a foam gun or a foam gun kit same as at screwfix . you can dial it down to a 5mm bead or out to 50mm plus and it won't go off in the tin like a lot of the one shot tins , you also get gun cleaner and heat resistant foam .
Lots of comments have been made that a hot wired wing would be just as good. IkyAlvin's method creates a molded stressed skin wing that is extremely strong and still pretty light. It also has some impact tolerance. In order to replicate the strength with a hot wired core it would need a fiberglass or wood skin added to it. That would result in a very strong but fragile wing. Slope planes lead a hard life so some resilience to impact is a good thing. Once the mold has been made many identical wing panels are easily created.
Absolutely brilliant!! I was thinking about using expanding foam also, but you beet me to it..... My idea was not nearly as elaborate and after seeing this, probably would not have worked anyway. If I ever get around to construction, I will definitely put your good ideas to use.
Thank you!
You have CORRECTED me , Sir!
I tried this when Expanding foam first came out...and failed so bad I thought it was a "dumb" idea, LoL!
I've used a similar process. Try this: make a thin balsa sheet, wet it, then put a carbon tube where you want the thickest part of the airfoil and wrap the now flexible balsa around it. CA glue the trailing edge, then fill with foam. Trim ends and you have a massively strong structure with no mold needed. Then, either use low-temperature heat shrink covering, or seal and paint. I've used this technique since 2002 and have had zero problems with it.
Excellent idea. This would be a very solid wing.
I used expanding polyurethane foam from a can to prevent strong winds lifting corrugated steel sheet on my workshop roof . (This had been laid over a flat felt roof which had begun to feel its age and started to leak). A one-second squirt into each of the raised metal corrugations. Worked fine, the wind did not lift the panels any more, but the foam just kept on expanding at a very slow rate for about a year until it was stable. Concerned that a wing section may change unless kept in a jig for a long time to stabilise.
looks like a nice alternative to using a hotwire, one day i might have to experiment using mylar sheets as a releasing agent so im left with just the foam core and so that i can vacuum bag fiberglass directly to it. thanks for shareing
I think it would have been better to use mix your own foam and have the mould on end then pore in the foam from the top it is easy to add to if you think you have not mixed enough and then just pore the extra in, I have used it for several projects I even repaired my rudder on my 40 foot sail boat after it split open by cleaning it out and taping up the rear then added the foam from the top I just watched it expand then when the expansion was slowing down just mixed more and added it this i did 4 times until it was full then re fibre glassed the back end and top and it was stronger than when it was new, I also built a new freezer using plastic board and filled the outside with it it ended up having around 6-8 inches on the base and 4-6 inches on the sides and top it would then freeze in less than 1/2 the time it use to take even though it was the same motor, pump and freezer plates it would pay for its self in the first year in using less power to run the pump than it use to also the pump came on less than half as often compared to what it use to which with it taking half as long to get the temp down and operating less than half as often it was actually only running 1/4 of the time it use to.
For a foam wing, this technique is more labor intensive, time consuming, and complicated than just hot wiring. And it also exposes one to chemicals, needlessly. IMP, it's a step backwards.
I've had great success with expanding foam and cling film! The cling film seems to bond with the expanding foam to make a really strong hard coating, a bit bumpy but awesomely quick for lids/housings etc. Would work well with a mould I'm sure.
I lay out the cling film spray foam on, mix it to remove air (and make a denser hard outer layer) then spray foam on top and add a top layer of cling film(with mixed foam as before). It's proper crash proof!
What? Sounds like a mess and way heavier than it needs to be. Have you never heard of laminating?
woow 6:46 this is amazing very good Lift-to-drag ratio
Now that was impressive. I can see that technique applied to other products, not just R/C flying...
This must have been the flying saucer I reported to the police on that day, thought I was going crazy. They are releasing me next month. Great work👍
excellence from simplcity! very efficient
Blocking off one end and having a restricter plate you can put on the open end would reduce the amount of foam needed.
very cool but I'm sorry, I don't understand what propels it forward. Is there a propeller not shown?
Nice - why not mold a spar right in? That would be a big advantage of this over hot-wire cutting.
Andy R, good idea - see my other video where I moulded in a wing brace for joining three sections together.
IkyAlvin n
Like your process
hey, I've been flying remote control planes, mostly gliders since I was about 14 years old and you did a great job on that man it flew obviously with most of the stuff we build from the ground up it's going to take a little bit of refining but damn good job sir
Great use of everyday, easy to get materials. Great build video.
super cool bro !
Audio narrative would complement the visual... Music is not needed, but a little background music might help when there is nothing else to say, so to speak...
Nice job!
use clingfilm and hairspray on the mould, fill directly with foam, done
Watt Waster. I guess it is not done after All
Yeah I used the cling film method - awesome speed and strength - not sure about the hairspray?
Yep, use this method for fiber glass molds with epoxy. Works great for the money.
How strong are these wings compared to EPP? I can make airfoil with 9mm EPP very quickly and by using carbon fiber tubes or fishing pole sections, they become indestructible and still very light.
looks like it makes a very strong wing... I like it.
Impressive work. Very clever idea.
Isnt there alot of waste of foam? They come out nice but as a beginner I think I will go along with a wire cutting device so much easier.
Idk why the thumbnail looks so delicious 😂
Try Locktite titefoam. it's more flexible and has a smaller, tighter foam structure. no large pockets of air that could weaken the structure of the wing
I was just about to post the same thing. I'm using it in clay molds (unrelated to RC) and it's fantastic!
Very good idea. It takes more work, but here you will get smooth surface instantly compared to hot wire. This is more suitable method for larger projects. Keep your good work :)
Why break up the excess foam? It can be carved into nose cones etc.
Fantastic Work and it Fly very well :)
im not a 'wing' guy, but video i loved.
good work!
Alvin, Look into 2-part mix & pour polyol foam. It's much easier to work with than a spray can and you will not have bubbles causing voids.
Just a thought, were does the waste go.... Can you eat it so it not wasted?
Nice clean wings good work, man.
cool build
I tried and tested like this for 25 years ago. After a week, the finished wing twisted.
Good job, but he's not really making a wing from expanding foam. He's eliminating the need for internal gussets and profiles for the Selitac folded wing.
Spot on. That is exactly what I'm doing. The foam strength and any voids are not really important as the skin is stressed. The foam fill keeps the skins apart and helps control the compression failure of the upper surface. Just like the common I beam.
Semantics. Sure looked an expanding foam wing to me.
I'll gladly trade mess for a master to make many wings quickly and easily
Is to.
@@joewoodchuck3824 It's called GPS blogs.illinois.edu/view/25/76120
From the thumbnail, I thought you were gonna cook a chicken ... I gotta get new glasses lol ;-)
Charles Roberts me too lol 😂
That is very cool!!!
Well-Done
Expanding foam is not necessary if you're going to use that outerskin. Could've reinforced inside with some laser cut wood for support.
I use this foam a lot for work and they do a gun specifically for it which is a lot more controllable and you would have a lot less expanding out of the mould. And you can re use it which is a bonus too 👍🏻 nice idea and a good result though
Nice, everything about this is very good. Flying the finished beast looks like a very tough challenge though with no fuselage or tail for directional perspective! I'd lose it in 6 seconds. This guy is pretty darn good! A1.
I am working on something like that and it seems lots of work was put it into creation of that wooden box. Is there an easier way to make the foam pressed like that?
I think there are lots of things you could try. A simple method might be to try making something out of foam that looked like the discarded top and bottom halves of a hot wire cut wing. Another interesting thing to try would be to use expanding foam to make an outside mould of an existing wing. Cling wrap/film can be used to stop the expanding foam sticking. The wooden frame may not be totally necessary but it keeps the mould straight and protects it. Why not make it in such a way that it can be reused? There are plenty of examples on CZcams of expanding foam destroying carefully crafted model boats - so bear in mind it can be powerful stuff. The most important aspect is that the moulded item is fully supported by the mould in all areas where the shape is important. The fit/alignment of the mound at the trailing edge is quite important. In later versions of the wing I have chamfered underlay at the join to get a thinner trailing edge. Good luck - make a video and let me know how you get on.
If you already have something to copy or can make a mock up some how you could use this technique.. Paint on silicon rubber that hardens into the mold. Then before removing from the object you molded, you coat the outside of the rubber with fiberglass to make the hard outer case to support the rubber mold. You coat the rubber mold with a chemical release agent, then put in the expanding foam. Then you have a mold that can be reused many times. www.smoothon.hu/antler%20reproduction.pdf
great job. if you want stronger versions, use split coroplast for the skins. very strong and stiff.
Old vid but great idea
Maybe use stretch foil for wing insulation. Have you added some fiber glass to that structure?
Very interesting. I have some canned foam somewhere. I reckon that if you could extend the nozzle on the can, you could make a much bigger wing, 8ft or even more! B¬)
the launch directly toward THE SUN! caused me to have to wear my sunglasses and I couldn't see anything....oh well! I'm not disappointed..
Interesting experiment.
Awesome... next time I'm out at the bar I want you to be my wingman.
You can be my wingman anytime.
Crowley, I don't think you understand what "wingman" means.
Kamran Ahmad Sure I do.
you know Aleister was a pan sexual right?....just sayin'
The best ❤️
nice video, but how do you fill the kerosine into that wing?
There is no way to get a consistant density. Your wing will be unbalanced.
Great idea, must do some experiments to see if there is enough flexibility and compressibility in the foam if you want to build longer wings or in case of crash so the frame would not fracture
Love how clever this is. Well done.
Nice idea, but when you only show text and pictures, you can also write a blog. Its way easyer and nobody expects to be entertained by a video with sound and speech. ;)
Very cool.
Nice job...!
Good concept. The plane is not V'd enough. Therefore it is unstable.
Wouldn't it be easier to just spray some foam spray in the air?
:)
nice job
is it normal to want to eat it?
This seems like an hugely excessive amount of work compared to hot wire. I can't see an advantage.
That the same thing I was thinking.
I need about 5 minutes for one 50 to 70cm piece of wing, from cutting the foam from the big piece, putting on the templates and cutting lower and upper side. Plus: the excess material is a good way to store the wings. They actually pile up on the shelve behind me.
Nice suggestion. Would be excellent for round shapes like noses or tails. Even modular fuselage sections would be possible.
Not to mention that is a very expensive wing to make. Those materials are much more expensive than cutting foam cores.
The sturdy skin would seem to be an advantage and would obviate need for shucks. And the idea is to re-use the mold. Maybe you can cut perfect LEs with a hot wire, but this method pretty much guarantees it.
the wing resistance is greater than Extruded polystyrene (XPS) ?
U can make a FlyingWing with Dollar Tree foam sheets that are far less labor intensive & messy!
I see major advantages it's a wormhole if the journey isn't your focus (building as a pass-time) and the resulting piece is in urgent demand
Wow. Thats tedious. Mad respect for him for taking the time to do it
Nice place to fly !
Es hermoso, es espectacular, es una maravilla, es grandioso el lugar donde vuela! Del ala lo unico que rescato es su construccion creativa y varata. Muy varata.
good idea of great video but an awful lot of work for something that cost peanuts to start with, really have to ask a question is it worth all the messing about?
It's polyurethane ?
very nice idea, very nice video, and flying not sure win but i will try your method. it does look like a lot of work for a wing but if you plan far enough ahead you could use the same Mould for several airplanes. great job and thank you for sharing
Nice work my man.
I love the look of the selitac :D like a vintage pop rivet plane.
It's called expanding foam because it expands. Why did you waste so much foam? That resulted in more work for yourself
Interesting method of producing foam wings. However,it does not appear to have any advantage
over the traditional hot wire cut foam method. Probably more expensive, messy and time consuming.
In my opinion your method has potential but needs more refinement. May I encourage you to continue,
you may start a wing making revolution!
What kept the frame foam from sticking to the master form?
Absolutely Genius !
Super cool video. tnx.
Did u use polyurethane foam?
No plucked chicken tickling here.
Extremly nice Idea!
Spray cooking oil on the table surface first. will help in cleanup
cover table with paint plastic or similar
A lot of work goes into making the molds.. making the wings looks easy part....
Great way to make a biplane wing.
what are the chances of air pocket or weak spots in the mold
I do the same but use 1/4" thick mylar bubble wrap instead of the board. Lightweight and makes a really nice wing
Very cool
Closed cell or open cell.. neat I would mold the fuel tanks in each wing you can carry triple fuel hmm damn they might say the boy is genius except. Thus is just pulling idea how the big boys did it that's all.. I would put battrys in wings to. Cameras lights . The options so cool I'm buildings a plane now.. thanks thanks rhanks
Thanks for the guide I'm making one right now! :-D
Make and post a video. I'd like to see what you develop.