Control Horns From Gift Cards or Cutting Boards

by dharkless | January 1, 2014 | (17) Posted in Tips

Hello out there.  I found a quick and easy way to make control horns from gift cards.  You can make either 12 smaller ones or 8 larger ones from one card.

First you draw lines to divide the card into either 4 or 6 equal rectangles. The card in the photo shows half and half. Then you draw diagonals to divide each rectangle into two triangles.  Next cut them all out using a stourt pair of scissors.

You should start with a smaller blank and draw a line 7/16" from the long side.  Cut off the 90 degree corner.  Then cut about 1/8" off of the other two corners.  Then drill 3 equally spaced holes along one end as shown in the photo.  You should leave at least 1/16 of material around each hole (a little more would be better).  I eyeballed them but they ended up at 3/16" centers.  I drilled 5/64" for 1/16" control wire. Mark this one "P" (pattern) and use it as a template to mark and drill the others.  Also use the small pattern to make the 90 degree cut-off and drill the holes in the first larger one.  Mark that "P" as well and keep it for your large template..  

Take a sharp knife and remove the drilling spurs from the back side of each before "painting".

The black coloring is magic marker.

These are quick and easy and best of all, FREE!

They should look like...

 

 

UPDATE:

For heavier applications I have used three of these together to make one stiffer horn.  First take one of the smaller ones and slot it into the control surface using the longest edge in the slot.  Then take the larger ones and glue one on either side (not slotted in).  Then run a bead along each side.  You may have to re-drill the holes. I used this on my 32" Raptor to good effect.

 

 

 

 

Update:

I ran out of expired gift cards so I scoured the house and found another very suitable material.  My wife is now missing one ofher reserved flexible plastic curting boards.  I just cut them into strips equal to half the width of a gift card using a knife and straight edge.  I and then cut them into sections equal to 1/2 the length of the gift card usinga pattern and scissors.  Then I cut the small rectangles diagonally and follow the rest of the method above.  TAhese are a bit more slippery when stacked so I have used a pair of vice gips to hold thew stack together while drilling,  This also keeps the holes more consistent.  I drill 1/16 for the flag wire push robs.  Sometimes they need cleaned out a second time for the wire to go through so i always keep a drill at the ready when doing rods.   

COMMENTS

rezq911 on January 2, 2014
Nice! Check out the ones I found.

http://www.flitetest.com/articles/the-cheapest-quickest-control-horns-ever
Log In to reply
dharkless on January 2, 2014
Thanks.
Yes. I saw those when I was checking to see if anyone else had submitted my idea. Yours is a very good idea as well.
Log In to reply
thejosh108 on January 4, 2014
very nice, I like that you use a $100 gift card... I ended up buying a 500 pack of blank cards On amazon for $30. Also, do you trust just gluing them on top, I always do like Ed and have a flap of card on the other side of the surface so that there is more to glue and grip.

https://www.youtube.com/watch?v=RpIdJX5Jagw
Log In to reply
dharkless on January 4, 2014
I slot them in like the wooden ones, through one side of the paper and against the second side. I widen the slot with a plastic mechanical pencil tip and fill the slot with glue. I then add a bead of glue on each side. They do soften when in contact with the glue but get firm again when cold.
Log In to reply
petedotnl on January 4, 2014
good recycling !!
Log In to reply
dharkless on January 7, 2014
And some people say that recycling doesn't "pay". I was just trying to save money.
Log In to reply
steadfast4life on January 6, 2014
Great idea! Isn't that what scratch building is all about? Love it.
Log In to reply
dharkless on January 7, 2014
There is always another way!
Log In to reply
balsa or carbon on January 22, 2014
Another material you can use for control horns is old scratched CD or DVD discs . Very strong ( polycarbonate ) , and can be cut with a Dremel cut off blade .
Log In to reply
IcyBird on February 15, 2014
Or you can use the cases for DVDs. I use those and they work fine with all the planes I have build.
Log In to reply
resp20 on April 21, 2015
I use gift cards to make my firewalls for swapables. just strong enough to hold motors.
Log In to reply
dharkless on April 21, 2015
That sounds like a good idea. If needed you could laminate two layers with hot melt for extra strength. How do you attach motors? Bolt & Nut?
Log In to reply
usarmyfl on June 1, 2015
I was thinking of doing this and now glad I see someone else who does. As Dharkless asked, how do you attach your motors?
Log In to reply

You need to log-in to comment on articles.


Control Horns From Gift Cards or Cutting Boards