Making model aeroplane wings from expanding foam

Making a 48 inch model flying wing from expanding foam and floor underlay. Low tech solutions. Materials, making the mould, moulding a wing half, making the flying wing and test flying.

[@Tryin2FlyII]

I had this idea a few years back but never followed through glad to see some else did AND did it! Nice job

[@benfelland]

Sweet idea. Always cool to see people build something themselves versus buying it at a store.

[@wayneshephard]

Good on you for trying something different, thinking differently, it gives you a nice smooth surface immediately, not a bad idea.

[@getslimdad]

I love the building of the models from scratch, so fulfilling. any method that shortens time, is a plus, 1st lesson I had to learn the hard waay was, not strong but "just strong enough" or they disintegrate on impact

[@EC6-USA]

Absolutely brilliant!! I was thinking about using expanding foam also, but you beet me to it..... My idea was not nearly as elaborate and after seeing this, probably would not have worked anyway. If I ever get around to construction, I will definitely put your good ideas to use. Thank you!

[@burnerjack01]

Couple of possible improvements: 1) Put down cling wrap on table to aid cleanup. 2) Maybe embed servos and electronics in wing before foaming or using cling wrapped blocks to make exact voids in foam for electronics. All that being said, great process, great results. Well done.

[@olsmokey]

I watched this for the dialogue. Best I've heard on YT

[@CarminesRCTipsandTricks]

The Banter is especially nice. 😋

[@phillipbywater2546]

This dude would not shut up.

[@rogerday6184]

Profoundly witty commentary!

[@dang25272549]

Nice clean wings good work, man.

[@JemmetGK]

Now that was impressive. I can see that technique applied to other products, not just R/C flying...

[@valderja]

Impressive work. Very clever idea.

[@RCHeliJet]

Fantastic Work and it Fly very well :)

[@jasonvaughn7934]

hey, I've been flying remote control planes, mostly gliders since I was about 14 years old and you did a great job on that man it flew obviously with most of the stuff we build from the ground up it's going to take a little bit of refining but damn good job sir

[@jjutbalajj8972]

Always wanted to experiment with expanding foam to make a wing. It always seemed so durable and like a great way to make a custom airfoil. Since it's so heavy I never gave it a shot. I never thought about making a slope glider...the weight is perfect to cut through heavy winds. Great demonstration of how it can be done!

[@harpoon_bakery162]

yes, indeed it's very heavy but very durable.

[@Waldenmattfinish]

Excellent idea. This would be a very solid wing.

[@wildmano1965]

looks like it makes a very strong wing... I like it.

[@bdrw8032]

You have CORRECTED me , Sir! I tried this when Expanding foam first came out...and failed so bad I thought it was a "dumb" idea, LoL!

[@CyberRecycle]

im not a 'wing' guy, but video i loved. good work!

[@jumanji-cs9ky]

woow 6:46 this is amazing very good Lift-to-drag ratio

[@onjofilms]

Nice work my man.

[@August80ify]

looks like a nice alternative to using a hotwire, one day i might have to experiment using mylar sheets as a releasing agent so im left with just the foam core and so that i can vacuum bag fiberglass directly to it. thanks for shareing

[@stevemcilroy9518]

This must have been the flying saucer I reported to the police on that day, thought I was going crazy. They are releasing me next month. Great work👍

[@howegav]

Great use of everyday, easy to get materials. Great build video.

[@bjarnehansen1101]

Extremly nice Idea!

[@georgeorwell8138]

cool dude. loved the vid

[@gordontarpley]

Really good idea!

[@alexabadi7458]

Nice place to fly !

[@JB-pt6kd]

I used expanding polyurethane foam from a can to prevent strong winds lifting corrugated steel sheet on my workshop roof . (This had been laid over a flat felt roof which had begun to feel its age and started to leak). A one-second squirt into each of the raised metal corrugations. Worked fine, the wind did not lift the panels any more, but the foam just kept on expanding at a very slow rate for about a year until it was stable. Concerned that a wing section may change unless kept in a jig for a long time to stabilise.

[@titaniumdiveknife]

Beautiful. Just beautiful. Thank you

[@moogybannahilstopaflingon6803]

Nice job...!

[@jfingerskeys]

cool build

[@blainsmith3097]

super cool bro !

[@rchammer3595]

I've had great success with expanding foam and cling film! The cling film seems to bond with the expanding foam to make a really strong hard coating, a bit bumpy but awesomely quick for lids/housings etc. Would work well with a mould I'm sure. I lay out the cling film spray foam on, mix it to remove air (and make a denser hard outer layer) then spray foam on top and add a top layer of cling film(with mixed foam as before). It's proper crash proof!

[@spammerscammer]

What? Sounds like a mess and way heavier than it needs to be. Have you never heard of laminating?

[@beauknowz]

That is very cool!!!

[@guygriffiths4950]

Thanks for the guide I'm making one right now! :-D

[@IkyAlvin]

Make and post a video. I'd like to see what you develop.

[@edgaruvinfokanal5817]

Very good idea. It takes more work, but here you will get smooth surface instantly compared to hot wire. This is more suitable method for larger projects. Keep your good work :)

[@David-tk4ru]

Lots of comments have been made that a hot wired wing would be just as good. IkyAlvin's method creates a molded stressed skin wing that is extremely strong and still pretty light. It also has some impact tolerance. In order to replicate the strength with a hot wired core it would need a fiberglass or wood skin added to it. That would result in a very strong but fragile wing. Slope planes lead a hard life so some resilience to impact is a good thing. Once the mold has been made many identical wing panels are easily created.

[@pops9190]

you clever man!

[@ChuckPlains]

Very interesting. I have some canned foam somewhere. I reckon that if you could extend the nozzle on the can, you could make a much bigger wing, 8ft or even more! B¬)

[@kamranahmad4592]

Awesome... next time I'm out at the bar I want you to be my wingman.

[@Crlarl]

You can be my wingman anytime.

[@kamranahmad4592]

Crowley, I don't think you understand what "wingman" means.

[@o.w.dobbins6927]

Kamran Ahmad Sure I do.

[@SomethingBlack]

you know Aleister was a pan sexual right?....just sayin'

[@demej00]

How strong are these wings compared to EPP? I can make airfoil with 9mm EPP very quickly and by using carbon fiber tubes or fishing pole sections, they become indestructible and still very light.

[@1dkollar]

Absolutely Genius !

[@TomTreeMan]

excellence from simplcity! very efficient

[@andyward8336]

if you use expanding foam regularly you would probably find it cheaper to get a foam gun or a foam gun kit same as at screwfix . you can dial it down to a 5mm bead or out to 50mm plus and it won't go off in the tin like a lot of the one shot tins , you also get gun cleaner and heat resistant foam .

[@charlesroberts2166]

From the thumbnail, I thought you were gonna cook a chicken ... I gotta get new glasses lol ;-)

[@diarts4458]

Charles Roberts me too lol 😂

[@randonguy_s50]

Idk why the thumbnail looks so delicious 😂

[@susie3702]

I think it would have been better to use mix your own foam and have the mould on end then pore in the foam from the top it is easy to add to if you think you have not mixed enough and then just pore the extra in, I have used it for several projects I even repaired my rudder on my 40 foot sail boat after it split open by cleaning it out and taping up the rear then added the foam from the top I just watched it expand then when the expansion was slowing down just mixed more and added it this i did 4 times until it was full then re fibre glassed the back end and top and it was stronger than when it was new, I also built a new freezer using plastic board and filled the outside with it it ended up having around 6-8 inches on the base and 4-6 inches on the sides and top it would then freeze in less than 1/2 the time it use to take even though it was the same motor, pump and freezer plates it would pay for its self in the first year in using less power to run the pump than it use to also the pump came on less than half as often compared to what it use to which with it taking half as long to get the temp down and operating less than half as often it was actually only running 1/4 of the time it use to.

[@jerrynewberry2823]

Great way to make a biplane wing.

[@guerrillaradio9953]

I've used a similar process. Try this: make a thin balsa sheet, wet it, then put a carbon tube where you want the thickest part of the airfoil and wrap the now flexible balsa around it. CA glue the trailing edge, then fill with foam. Trim ends and you have a massively strong structure with no mold needed. Then, either use low-temperature heat shrink covering, or seal and paint. I've used this technique since 2002 and have had zero problems with it.

[@lenny108]

nice video, but how do you fill the kerosine into that wing?

[@bjl1000]

great job. if you want stronger versions, use split coroplast for the skins. very strong and stiff.

[@andrewerickson6690]

Old vid but great idea

[@hillock10]

For a foam wing, this technique is more labor intensive, time consuming, and complicated than just hot wiring. And it also exposes one to chemicals, needlessly. IMP, it's a step backwards.

[@jeffswope1511]

Like your process

[@ConsertandoTudo]

the wing resistance is greater than Extruded polystyrene (XPS) ?

[@freesaxon6835]

nice job

[@joewoodchuck3824]

What kept the frame foam from sticking to the master form?

[@pe4153]

Very Impressive

[@carlosgo6882]

Es hermoso, es espectacular, es una maravilla, es grandioso el lugar donde vuela! Del ala lo unico que rescato es su construccion creativa y varata. Muy varata.

[@dagobb]

Nice !

[@pierdolio]

Interesting experiment.

[@FamousInternetGuy]

neat!

[@gunner4q]

the launch directly toward THE SUN! caused me to have to wear my sunglasses and I couldn't see anything....oh well! I'm not disappointed..

[@minor0confusion]

use clingfilm and hairspray on the mould, fill directly with foam, done

[@JoshWeaverRC]

Watt Waster. I guess it is not done after All

[@rchammer3595]

Yeah I used the cling film method - awesome speed and strength - not sure about the hairspray?

[@Mjr._Kong]

Yep, use this method for fiber glass molds with epoxy. Works great for the money.

[@dronesvisionsaeriennes]

Excellent....

[@EngineerNick]

nice one :)

[@Blooper1980]

NICE!

[@dieselscience]

Alvin, Look into 2-part mix & pour polyol foam. It's much easier to work with than a spray can and you will not have bubbles causing voids.

[@isaiahhiggins]

so satisfying

[@jamescunliffe9872]

Like welding without a mask in bright sunlight?

[@jennyinpink22]

Nice. 👍

[@TrentPierceProjects]

Love how clever this is. Well done.

[@jerrynewberry2823]

Spray cooking oil on the table surface first. will help in cleanup

[@cedricpod]

cover table with paint plastic or similar

[@InTheFleshInc]

@6:03 I can envision making a mini ultra with that wing shape...Awesome

[@sonawarali6192]

InTheFleshInc

[@icegiant1000]

Great job!

[@farmers2630]

Very cool.

[@mattirissanen8163]

Damn. I thought I read "exploding foam". Well...why not?

[@Boemel]

I love the look of the selitac :D like a vintage pop rivet plane.

[@jelleterpstra65]

Great master

[@garryperrin2408]

Cool! Where were you flying?

[@craigkeller]

Very cool

[@markellii3093]

Everything used in this video is expanding xD

[@andy347]

Nice - why not mold a spar right in? That would be a big advantage of this over hot-wire cutting.

[@IkyAlvin]

Andy R, good idea - see my other video where I moulded in a wing brace for joining three sections together.

[@trumpnut]

IkyAlvin n

[@incubusfan4211]

I have used this method for creating "nerf" footballs. Great job. My wallet thanks you.

[@sputnik4216]

Nice, everything about this is very good. Flying the finished beast looks like a very tough challenge though with no fuselage or tail for directional perspective! I'd lose it in 6 seconds. This guy is pretty darn good! A1.

[@user-xp7ls6sj8r]

wonderful

[@fazzyman136]

Wow. Thats tedious. Mad respect for him for taking the time to do it

[@piotrlenarczyk5803]

Maybe use stretch foil for wing insulation. Have you added some fiber glass to that structure?

[@reefer2917]

Well done great vid very educational, how does the wing go for radio reception? I would imagine all the alloy on the wing surface would play havoc for the Rx, I imagine sloping you don't go so far, but does it interfere on longer distances to your Rx?? I suppose you could use plastic sheeting for the skin and that would solve the Rx problem?

[@IkyAlvin]

I'm using a DT micro Rx with old Spektrum dx6i TX. not noticed any range problems, but then not extensively tested either.

[@arthurdent15]

IkyAlvin

[@brianparr1760]

tilo böhme hn

[@redsampler2017]

its not alloy, its plastic foil that only looks like alloy over a layer of 5mm foam its used as underfloor, to go under the topfloor like laminateflooring, you can compare the reflective foil with a thinner version of ''car wrap'' its available in gold color too, i have sold that stuff for years, there is even adhesive tape available of the same stuff (looks in fact like reflective packing tape) to cover gaps and to keep it nice together without ''coldleaks'' you can in fact make awesome lightweight and sturdy models with that stuff.

[@fetymann]

It's a vinyl wrap. Don't be afraid to use Google.

[@DrengrWolf]

Try Locktite titefoam. it's more flexible and has a smaller, tighter foam structure. no large pockets of air that could weaken the structure of the wing

[@ElizabethGreene]

I was just about to post the same thing. I'm using it in clay molds (unrelated to RC) and it's fantastic!

[@4seeableTV]

Well done.

[@moonscrafts8987]

The best ❤️

[@marcelojaviertwt]

*MIRA QUE LINDO!*

[@jeffbeck6501]

Good concept. The plane is not V'd enough. Therefore it is unstable.

[@MrWombat57]

Blocking off one end and having a restricter plate you can put on the open end would reduce the amount of foam needed.

[@AlfredWheeler]

Audio narrative would complement the visual... Music is not needed, but a little background music might help when there is nothing else to say, so to speak... Nice job!

[@tombouie]

Well-Done

[@bernardopatino6263]

Super cool video. tnx.

[@Ivar1231]

Seems like a lot of work...

[@jorgenelsonfelix52]

😃 Fantástico 😃 👍👍👍👍👍

[@makewhatyoulike119]

very cool but I'm sorry, I don't understand what propels it forward. Is there a propeller not shown?

[@isaiahhiggins]

This guy must work at an expanding glue factory