Hot Wire Wing Cutting

A video showing the start to finish process of cutting out a wing using a hot wire bow. I wanted to demonstrate one way to go from a sheet of insulation foam to a finished wing core. This is the technique that has been working for me so far. I am sure there are many ways to improve on the process, please share your tips in the comments.
Thank you to all of the folks who have taught me how to do it! In particular the guys of Garage Rats, Flight Club, FirmCore, Convict State Wings, and Team Hazard.
Sources:
Foam: Home Depot 2" x 4' x 8' R-Tech R7.7 Rigid Foam Insulation
Airfoil plots: airfoiltools.com
Charger for powering the hot wire: Tenergy TB6AC + 80W
Airfoil templates: phenolic sheets, 0.093" x 12" x 24" bought from Amazon.
Spray adhesive: 3M Super 77 spray adhesive
Nichrome wire: 26 guage, from Amazon.
"Automated" foam core cutter: Curtis Suter has an excellent PDF available online of how to build and use the drop arm pull device (also called a feather cut device) I show in this video. We used his instructions to build the hot wire bow and the pull device. There are several KZbin videos on how to setup and use the cutter. It was originally sold as a kit, Feather Cut foam cutter from Tekoa. Apparently the kit is no longer sold new but can be found used from time to time.

[@ilaymyheadonthesand]

I have seldom been so astonished by mans ingenuity.

[@nicholasn.2883]

The most useful video in the history of KZbin videos

[@rckeith]

Nice tutorial. I use to do it this way and it is a good way to get into foam cutting. My Vickers VC10 was built using the same feather cut system. I now use my own design CNC foam cutter which I've built many wings and fuselages on. 👍👍👍

[@PacificSword]

Cool to see how you did it. Thanks again Jeremy for the Big Mac cut. She's ready to maiden. This summer when I'm down there I'll maiden with y'all.

[@lostwing]

It will be great to fly with you all again!

[@ngoweyseong3738]

The idea and method for foam cutting is brilliant. Great job.

[@deldridg]

Great video mate. I'm inspired to do 2 things now: 1. pull apart an old corflute (coroplast) wing and rebuild with foam, using my shiny new... 2. ...Arduino powered cutter (which I haven't yet built but am inspired to now)! Many thanks and cheers from Sydney, Aust - Dave

[@lostwing]

It was definitely a learning process, but SO worth it. We can now build and fly just about any design we want. We were doing lots of R&D until we fell in love with the latest design - the Manatee. It just flies so damn well!

[@grahamlongley8298]

Brilliant video . extremely helpful Especially the view of the drop arm. Thanks.

[@ian3fs]

Watching him do this is person is even cooler. Nice tutorial J.

[@kurtjurgen]

impressive that you can actually cut that accurately enough with the wire

[@pethair]

He speaks so gentle

[@lostwing]

He touches gentle too

[@Andrew-gw6li]

And I was having trouble sleeping, thanks Jeremy

[@lostwing]

No problem. Best treatment for insomnia on the internet.

[@guloguloguy]

IF YOU WERE TO STAND YOUR FOAM BLANK UP, ON EDGE, WITHE THE TRAILING EDGE DOWN TOWARD THE TABLE, AND LEADING EDGE UP, TOWARD THE CEILING), AND CUT MOSTLY IN THE VERTICAL "UP" DIRECTION", YOU MIGHT GET SUBSTANTIALLY CLEANER, FASTER CUTS, (BECAUSE THE WIRE WOULD BE CUTTING INT PREHEATED FOAM, (FOAM HEATED PRIOR TO THE PASSING OF THE WIRE,.. USING THE ADVANTAGE OF THE "RISING HEAT"...

[@AlanzFPV]

Best part: “... once you get it going and you’re doing a few of these for your buddies, you’ll have it lined up...”

[@lostwing]

Ha!

[@michaelmueller9635]

Very clean

[@kev4354]

Wow that's clever - Thanks

[@bradruffalo]

well done!

[@gygaxthegoat2491]

EXCELLENT tutorial. Thanks mate. Subbed

[@tonyvelasquez9432]

Awesome tutorial Jeremy!!

[@lostwing]

Thanks man!

[@bigglesbiggles2072]

What a brilliant idea great video well done that man

[@skylords2608]

What a great video. Thanks for making it.

[@seanparker571]

Thank you

[@lostwing]

You're welcome

[@cliffordinggs9789]

phenomenal

[@charlesmyers9765]

Could you do a video of a manually fed cut vs using this pendulum fed? Would be interesting to see the difference, and if the PF is worth adding to the TWC. Thanks.

[@lostwing]

Good idea. Not sure if we will make that but will consider.

[@DefiantWings]

That’s a slick setup! I don’t know what wire you are using but you should look into René 41 wire. It’s what most of us use and it works so much better then nichrome. It doesn’t stretch as much when it heats up. I use 27ga. It more expensive but I only have to change it out about once a year.

[@lostwing]

Thanks! I will definitely check that out! Do you have a good supplier to recommend? The wire I have been using is certainly nothing special, I'd love an upgrade.

[@thenatedog]

@@lostwing yep rene 41 27 or 28g wire is awesome.

[@thenatedog]

Awesome!

[@terminsane]

I bet an arduino and 4 stepper motors could bang these out with a lot less fuss That said, i really like the simplicity in this method youve developed.

[@tombarton1]

Too cool

[@macbenac777]

hello, Hello, Please can you indicate the dimensions of the wing (length, tip chord, chord, sweep) and the profile used . Thank you very much. Great job.

[@NOXFPV]

Liked and subbed.

[@lostwing]

Thanks!

[@russcole5685]

What is the profile number you're using for the root and tip

[@jamesomega]

I don't remember if you've moved on to CNC yet, but have you tried adding a foam board shim under the leading edge of the block to assist the initial wire entry instead of pencils? It looks like the pulley forces pull backwards and down, so tilting the leading edge up a little bit might help the wire get around that first curve without needing an assist. My CNC build is taking forever but I think I'm going to build one of these for Nick to mess around with.

[@TheSkyIsCalling]

Good idea! I’ll give that a try next time. I‘ll have to see how it impacts the trailing edge too. The bow can get pretty close to the table on that side.

[@Purusotaman]

Great setup... Please share the airfoil template used for both centre and tip..

[@lostwing]

Check the other comments. I think Jeremy may have put some info in there.

[@Purusotaman]

@@lostwing Please share the dimensions of the template

[@PGriffin316]

Great video. Are you going to do a follow up to this one? Finalising the build? It's really hard to find a reasonably priced wing in Australia. I wouldn't mind heading down this route and start building my own.

[@lostwing]

That’s a good idea, we probably should do something like that. We learned everything we know about building wings from cats Firmcore, a small outfit that makes wings in Northern California. Why don’t you hit up David Foster with Team Hazard? I’m not sure if he is cutting these days but he may have some old blanks lying around he’ll send you.

[@lostwing]

You should definitely try cutting your own. It takes some trial and error to get the cuts to come out properly but the end result is worth it.

[@Sandokans]

What weight is needed? Below table is some water bottles?

[@440haste]

What is the best sweep for a wing?

[@145bar]

Hey, is there any chance to get the airfoil and drawing of that wing?

[@145bar]

??

[@bizzfpv]

I'm a little puzzled about what keeps the hotwire flush to the template? Is there some tension in the ceiling line to pull upwards?

[@lostwing]

I will have Jeremy get back to you.

[@lostwing]

Good question. The hot wire glides along the top of the airfoil template so gravity keeps it flush. The bow I use uses steel rods so they have some weight to them which helps. I am also sure to have the bow at a relaxed angle, maybe 45 or so degrees, so as it moves across the wing panel the wire stays flush. Around 16:00 shows the general way it moves over the airfoil. For the bottom I just turn over the entire wing panel and do it again. I hope that helps. If not let me know! Jeremy

[@bizzfpv]

That makes sense. In the video it looked like the wire was cutting to the under side of the template.

[@nicholasn.2883]

Do you think I could build this in a weekend?

[@lostwing]

Yes, but a long weekend!

[@davidlee50]

Do you make Cores for clients?

[@lostwing]

No. Just a hobby.

[@mdtofazzalhossain3600]

Where can I get this airfoil template?

[@waseemshah5865]

Pdf plans

[@wingsmh27]

What's the size of wing?

[@lostwing]

We have different size wings. The smallest is about 37" and largest is about 52".

[@wingsmh27]

@@lostwing thanks dear, happy flying 😎

[@wingsmh27]

@@lostwing and just one need ,what is the root chord size,sweep size

[@thenatedog]

I never did have any success using a bow.

[@guloguloguy]

THANKS, FOR THIS DEMO, [...BUT, ....FYI: IMHO: YOUR AUDIO IS TOO LOW/MUFFLED/POORLY ENUNCIATED... (STOP MUTTERING!!!...=> TALK LIKE YOU'RE TALKING TO YOUR ELDERLY MOTHER!...)...USE A PROPER MICROPHONE, AND, EDIT OUT THE BACKGROUND NOISE, OR, NARRATE/OVERDUB THE VOCAL DESCRIPTIONS,... AND USE A CAMERA TRIPOD (NOT HANDHELD (OR GET SOMEONE WITH STEADY HANDS, TO FILM YOUR ACTIVITIES...]

[@lostwing]

Good tips. This was a spontaneous idea. Next time we’ll do it right.

[@myvideointube]

Is there a link to the drawing?