Tips and Tricks

Cutting Ailerons From a Foam Wing.

I have found some steps that seem to help me get this done fast and accurately. Daniel Spurlock and I worked the kinks out of this method and killed some straight edges in the process. I have one 48” ruler that I use only for cutting out surfaces because it has some marks in the edge.

Lay out the cut lines on the wing (or whatever you are cutting). It is important to make sure the aileron is on the right side of the layout as it will go through the band saw. If the wing is to the left of the cut, it will not fit through the saw and you will end up laying it out on the other side of the wing.
Tape a straight edge on the surface lined up with the cut line. Notice in the photo that I am careful to have the straight edge over the wing so that any cutting error is in the scrap stock. This is key to the process.

After the tape is on and the straight edge is secure, set up the band saw so that there is ample room around it.
Set the guide on the band saw as high as it will go and cut along the ruler keeping the blade in contact with the ruler at all times. I can hear if the blade is on the ruler. This gives an arrow-straight cut, I do not sand it before white-gluing the balsa to the cut edges.

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