After putting 3 lookalikes here is my own design 40 Inch WS glider planned for 3 CH.

Hot wired wings in HD thermacol.

Aim is to have max flying with min power system.

Great build ... Hats off ....
By the way what density foam are you using ?

24 density.... but still it needs spar and reinforcements of paper and fevicol.

wowwwwwww  superb Saurabh sir  looks like factory made. 

Hey Saurabh thats awesome cut!!!!
how u manage to cut tips.
planning to cover wing with paper???
this build is very quick and handy!!!!!

Hot wire.... cut.....
I Plan to cover with paper and fevicol.... but off late feeling this is very tedious process and long... moreover lot of precaution is required to keep the wings under pressure so that they do not Warp...

looking for substitute.... tried the lamination film on thermacole but the heat for that is higher than thermacol limit so thermacol gets blisters...!!! 

anyway search is on....!!!

How about wrapping it with paper/tissue without sticking it, and then using lamination film. It should take off some heat off the thermacol. Maybe cooling the wings/parts in fridge before laminating, I know it sounds funny, but worth a try since you are already on it.

Superb Cut!

SideWinder - thermacol supposed to be the best insulator ..... in old days people used to keep ice in it for long hours  .

still thanks for the tip.

Try pro-coat or ultrakote ... I have coated a biofoam funjet with pro-coat   it works well

saurabh, what I meant was regarding wing tips, we generally stick 2 template at both ends, and run hotwire over it. and mostly keep both template parallel. So both the edges are parallel, at center and tips.
But in ur case, tips is not parallel to center but still u managed to get perfect circular tip, how u did that

Speechless............

Great cutting ... absolutely awesome

Quote from: rastsaurabh on March 27, 2014, 05:07:26 PM
SideWinder - thermacol supposed to be the best insulator ..... in old days people used to keep ice in it for long hours  .

I completely missed that point. And trust me its not outdated, still used in present times. Used it on Holi recently.

Ash - when you want a parallel wing you put template at both ends ..... but i use one template and hook one end of wire at a point and move other end on the template.....
see this video you will understand.

http://www.rcindia.org/for-sale/wing-core-made-of-high-density-thermacol/msg154985/#msg154985

VC - this one i made from the scrap thermacole left over after cutting the main planes... funjet and 40" trainer... and this is getting more comments!!!!

@ Saurabh Have you tired Packing tape for wrapping HD thermocole Its a good combination. Its shrinks well with sealing iron. Only care required is to shrink in multiple passed all directions with medium heat checking repeatedly to prevent warping or bending.

By the way superb cut.   

after paper stick i do tape them....and iron them.... but Paper with fevicol is a must as i experience...

with added paper and fevicol wrapping, yes the warping is prevented to a great extent but at the loss of added weight.

The packing tape wrapped HD Foam heat shrunk has a good strength with huge weight advantage.

I used to try deliberate warping for better wing design like polyhedral tips.

Never had warping in thermocole.
Why should it?
Doesn't absorb water.

@K K Iyer ... Yes it does warp ... Though it down not absorb water what happens is when u apply fecoicol and paper on one side .... And as it dries it shrines causing a bend towards the applied side .... To avoid this its should either be kept under pressure or both surfaces should be applied simultaneously.. And left to dry

One more good option is using good gsm paper and stick to thermacol, with putting some weights above , so that it does not loses its shape while drying.
Here is a good video if it.

What is that paper he used for covering, is it gsm paper? Whr is generally available

I had seen this earlier ... but couldn't find this paper anywhere...