Bixler Scratch Build (Hot Wire Foam Cutter)

Bixler Scratch Build - Plan/Templates

Used Parts:

2200kv / 180 W / 25-27 A Brushless Outrunner

HK-15339 Micro Analog Servo 7,5g

Hobbyking SS Series 25-30A ESC

TGS Sport 5x5E Precision Propeller

1300mAh 3s LiPo

At first i cut out the templates of normal cardboard.

Attaching the templates of the fuselage onto the foam. I use EPS foam (the cheap one).

Make sure that the templates are exactly on the same place.

Cutting out the fuselage using the Hot Wire Foam Cutter (it's the same technique as David's Hot Wire Cutter, just built as an scroll saw)

Cutting out the wings (it is easier with 2 people). Use one template at each side of the foam. I use a 55-60cm Hot Wire Bow. One wing is exactly 50cm long.

Cutting out the wingletbows using the same technique.

The width of the winglet is as long as the template of the airfoil.

Bend the winglet template that it fits into the 'bow'.

Cutting out the winglet and cutting off the edge.

Sanding the surfaces of the fuselage + wings.

Glueing the wings with the winglets together. Be careful: Don't use Hotglue or Superglue for EPS foam.

Sanding the edges of the winglets.

Putting some strapping tape on the frontedge of the wing.

Cutting a slot in the wings to put the carbon fiber rod in it. The slot is 6,5cm from the frontedge away.

Glueing the wings with the fuselage together and cutting a 2,5 cm slot into the fuselage.

Glueing in the carbon fiber rods.

Filling the slot in the fuselage with a piece of foamboard. Cover it with some strapping tape.

Cutting out the elevator/rudder of 5 mm foamboard.

Beveling the hinges of the control surfaces and glue control horns on it.

Cutting holes for the servos into the fuselage and glue them in.

Glueing the tail onto the fuselage.

Cutting off the canopy and cover the nose with strapping tape (i covered the whole fuselage with strapping tape).

Milling out the fuselage for your batterypack.

Covering the hole with some strapping tape.

Attaching magnets on the fuselage and the canopy.

Putting a stick under the canopy and cut a slot in the fuselage.

Glueing the firewall (Plywood) onto the fuselage and connecting the electronics.

Ready to fly it.

Maidenflight (i had to put some weights under the nose because it was tail-heavy):