Fygar
Junior Member
Anyone every try to build and FT Flyer out of plywood?
No not really. I did make templates for an FT Flyer though. A much cheaper alternative to springing for your own laser cutter. This makes building another very fast because you only have to print and tile together the plans once.
If you would like to try, just make up the tiled plans like normal. Use spray adhesive to glue the plan onto a piece of ply. I used a piece of 1/8" "Hobby Ply" I found at Lowes. It has a smooth veneer finish on both sides and was less than $20 for a 4' x 8' sheet. I used a jigsaw to cut the shapes out. I have a 6" wheel sander so I cut a little on the outside of the line and sanded it to shape.
The slots in the wing are tricky. I drilled a couple of holes to make an opening big enough to get the jigsaw blade through. To even up the edges of the slot I used the spray adhesive to glue sandpaper to a thin piece of metal (actually a galvanized strap leftover from my deck). For the inside cuts like the slot for the control horns I drilled 1/16" holes at either end. Then when you cut out the foam board you can just poke through the foam with a piece of control rod and finish the cut between the holes with a knife later. I also drilled a larger hole at the two CG reference marks big enough to get a Sharpie through to mark them.
Once I had the pieces all cut out I sprayed them with Minwax quick dry polyurethane. That will protect the plan glued to the top so I have the marks for 50% cuts and other reference lines.
Making the templates definitely took a while. It wouldn't be worth it for just one or two builds. Now I am thinking ahead to my next plane. Once I can keep a Flyer alive for a few flights I want to try the Old Speedster. I love the lines on that plane. Cutting the curves is another matter. I think I will try the templates again so I don't have to cut the curves freehand.
I will let you know how it goes.
No not really. I did make templates for an FT Flyer though. A much cheaper alternative to springing for your own laser cutter. This makes building another very fast because you only have to print and tile together the plans once.
If you would like to try, just make up the tiled plans like normal. Use spray adhesive to glue the plan onto a piece of ply. I used a piece of 1/8" "Hobby Ply" I found at Lowes. It has a smooth veneer finish on both sides and was less than $20 for a 4' x 8' sheet. I used a jigsaw to cut the shapes out. I have a 6" wheel sander so I cut a little on the outside of the line and sanded it to shape.
The slots in the wing are tricky. I drilled a couple of holes to make an opening big enough to get the jigsaw blade through. To even up the edges of the slot I used the spray adhesive to glue sandpaper to a thin piece of metal (actually a galvanized strap leftover from my deck). For the inside cuts like the slot for the control horns I drilled 1/16" holes at either end. Then when you cut out the foam board you can just poke through the foam with a piece of control rod and finish the cut between the holes with a knife later. I also drilled a larger hole at the two CG reference marks big enough to get a Sharpie through to mark them.
Once I had the pieces all cut out I sprayed them with Minwax quick dry polyurethane. That will protect the plan glued to the top so I have the marks for 50% cuts and other reference lines.
Making the templates definitely took a while. It wouldn't be worth it for just one or two builds. Now I am thinking ahead to my next plane. Once I can keep a Flyer alive for a few flights I want to try the Old Speedster. I love the lines on that plane. Cutting the curves is another matter. I think I will try the templates again so I don't have to cut the curves freehand.
I will let you know how it goes.
