FT Flyer scratch build - complete with newb errors

[BeezerFish]

Just finished (minus the electronics which haven't delivered yet) my first scratch built plane and wanted to share my experience/observations with the community. This is semi lengthy so please bear with me...

I began by printing out and gluing/taping the plans together into one giant set of prints. I then used some tacky spray adhesive to place the prints onto my DTFB. To make things easy on myself, I even labelled the pieces so I knew what each piece was going to be. So far so good.

With the DTFB and prints laid out on the garage floor, I used a new box cutter blade to carefully cut out the pieces. Using a yard stick and making multiple passes to make each cut, I'd estimate it probably took me 30 minutes to cut out all of the pieces. I didn't realize this until I went to put the plane together, but instead of flipping the template for the wing over to finish the other half of the wing I rotated the template 180 degrees. This resulted in my cutting a slot in the right wind about 1" from the leading edge of the wing and a similar slot 1" from the rear edge of the left wing.

Following along with the build video on YouTube I was able to build the fuselage and tail assemblies with little issues. It was when I attempted to join the wing and fuselage together that I realized my mistake with the wing template. Thankfully I was able to add in the missing slot after the fact (not the ideal situation) and finish assembly of the FT Flyer. Once the electronics deliver I'll install those components and probably add a set of Nutball skies so that I can maiden my Flyer over the winter instead of waiting until spring. All in all, this was a great first plane to tackle as a scratch build and the build video/community input were invaluable. Here's some of my observations as I think about a second scratch build:

1) A sharp blade is key
2) Take your time with each cut. Trying to cut through the DTFB in one pass leads to very jagged cuts
3) I always tried to setup my yard stick in such a way that if my blade wandered I would not veer into a a part of the plane, rather I would just cut into excess DTFB
4) Watching the build video ahead of time and while assembling the plane seemed to work best for me. The first watch through was so I would have an idea of what was going on ahead of time and would hopefully make the actually build go smoother
5) Make sure the voids for the A and B cuts are completely cleaned out otherwise the folds don't have nice crisp lines
6) Hot glue is really hot

I do have a couple of lingering questions for the community based on my experience:

1) What are other people using to make the smaller cuts? The box cutter blade worked ok, but I feel like there is a better tool for the small detail cuts
2) Do most people lay out the part templates in one sheet like I did or can I cut out the templates ahead of time and lay them out individually on the DTFB? I feel like had I done this method, I could have potentially made a second Flyer from one sheet of DTFB
3) In the Hot Glue tips episode, Josh mentioned placing a bead of hot glue the edges of the DTFB in an effort to keep the paper from delaminating. Is this step best done before or after the plane is assembled?

I've got pictures of the process but for some reason I'm having issues getting them posted. I'll get pictures posted if possible

Thanks for reading/any feedback you might have

 

[PhenomPilot]

Congrats on the build! Your tips are spot on. The flyer is a great beginner plane and and can be a fun intermediate with a hot motor
1. Box cutter blade is good until you get to the corners or curves then I use the exacto knife.
2. I typically tape the pages together then cut out the patterns to lay on the DTFB. Then I trace the patterns and cut the foam. I would be impressed to see two flyers cut from one sheet but you could probably get three cut from two sheets.
3. I haven't glued the leading edge but I usually do the rudder. It won't matter the order because you can take the power pod off and glue the wing. I typically use extreme packing tape or BBQ skewers and tape on the leading edge.
Once you start doing loops, it is important to glue a BBQ skewer on top the wings to keep them from folding under load. Good luck with the maiden!

 

[IFlyRCstuff]

Awesome tips, and the FT Flyer is a great plane. With the fine details I prefer to use a very small, very sharp blade that I get from accidentally breaking a box cutter. I usuall apply the hot glue for the leading edges (if it doesn't have an airfoil or KF step) after I have test fit everything. Some people also glue barbecue or fiber glass rods to the leading edges. You will probably also want to reinforce your power pod. To do this, drill holes in used credit or gift cards that match the barbecue holes, and glue to match. I also find it helpful to glue barbecue skewers or craft/popsicle sticks to the in side and cut down to meet the back edges.
HAPPY FLYING!!!