Foamie Wing Jig

Building a Foamie Wing Baking Jig

Many of the foam plane plans call for a formed wing. This is can be accomplished easily with a Wing Baking Jig.  The Wing Jig is sized specifically to fit on the rack of a typical house oven. Just 15 mins at 200 degrees will turn the Fan-Fold foam in to a nice airfoil. Baking is an amazingly quick way to to build a wing.

Plans for the Wing Jig can be purchased from FoamFly.com here. Though I decided just to wing it on my own with out plans once I understood the design. The key piece of the design is knowing that the forming sheets are made from scraps of flashing supported by airfoil ribs. A see photos below.

Steps

  • Cut one a piece of 3/4″ ply 12″ x 20″.
  • Cut two pieces 1 1/2 ” x 20″ of 3/4″ ply.
  • Cut 4 or 5 slots 1/4″ wide. Cut the slots tight so the support rib fit snug.
  • Using the dihedral support template from the Foamie plane plans, cut 4 or 5 airfoil ribs of 1/4″ ply making sure to add the depth of the slots. Increase the airfoil shape 10% or so in sharpness. The curve needs to be a little tighter as the foam will bounce back a small amount after forming.
  • Cut two 20″ pieces of aluminum flashing. Crease the flashing 1 1/2″ from front edge.
  • Clamp the all pieces in place with C clamps and drill the front and rear clamping bolt holes.
  • With the ribs in place bolt down the bottom sheet of flashing. The nuts create a gap between the flashing sheets that is the space where the the foam will sit.
  • Insert the foam wing making sure to keep the front edge lined up and strait. If the foam is missed aligned the curve of the airfoil will be.
  • Using the 1 1/2″ bars clamp down the front and rear of the top flashing.
  • Bake for 15 minutes at 200 degrees. The wood will not burn but will be hot. Let the the foam cool in the jig.