Step 1
The first step in making the foamboard model was getting the plans printed. At first, I attempted to print them in multiple a4 pieces of paper which I would glue together but that was far too difficult to get perfect so I instead got the entire plans printed on one a2 size paper at Officeworks.
Step 2
Then I attached the printed plans to the foamboard using thumbtacks so that they wouldn't move around but would be easy to remove without damaging the foam. Then I cut the foamboard following the plans using a hobby knife and a ruler wherever possible, precision is highly important so I took my time with all the cuts and made sure that the knife was always perfectly vertical so that all the cut edjges are perfectly square.
Step 3
At this point, I have cut out the parts for one half of the plane. I tried attaching the inner pieces to the outer foam shell to check how they fit and I was pleased with the perfect tight fit that all the parts had. Also, I used the other end of the knife to enlarge the slots behind the leading edge of the wing, this is to make folding the wing over easier.
Step 4
After completing step 1, 2, 3 and 4 for the other side of the wing, I glued all of the parts to one side using a hot glue gun. I glued all the interior structural foam in place to the bottom side as well as the all of the electronics except for the electronic speed controller because it will be going on the outside as it requires more airflow to keep cool.
Step 5
Then I folded the top of the foam over on the crease lines making sure to line it up correctly both with the back edge of the wing and with the slots on the interior structural foam pieces, again gluing in with a hot glue gun. At this point, it is almost finished with the main wing being complete and is far lighter than expected.
Step 6
Finally, I glued the motor mount and attached the motor and wired it into the rest of the electronics, and was ready to take it for a test flight. But unfortunately, I had miscalculated the centre of gravity of the plane and it was too far back. So I made a shorter motor mount and moved the battery as far forward as possible, but it was not enough so I had to add 75g of weights to the nose of the plane to get the centre of gravity exactly where it should be. Now the plane is complete and ready for the maiden flight!