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    My foam cutter

    Here's the last thing I cut. 72", .5mm nichrome 'bow' @36v with a very carefully calibrated tensioner.
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    Matty's Marvelous Modular Monstrosity

    I got all the big bits out from under the build table the other day and laid them out on the grass. Gonna need a bigger garden. I'm almost at the stage where I start having nightmares that none of them fit together!
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    Matty's Marvelous Modular Monstrosity

    I've finally managed to cut a perfect mould! 1.8m in one pass. Now I've run out of big moulds to cut I'm pretty sure I've got the process nailed.
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    Matty's Marvelous Modular Monstrosity

    There are these plastic bearings that I might use in place of bronze bushings so I'm already maybe heading in that direction! https://www.igus.co.uk/iglidur/plain-bearing?sort=3&inch=true
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    Matty's Marvelous Modular Monstrosity

    Sometimes I stop and give thanks that I'm still allowed to use metal cutlery.
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    80% Scale Hawker Hurricane

    Here's a link to the ssdr one (pdf) Https://www.aerosociety.com/media/10193/martyn-ing.pdf
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    Matty's Marvelous Modular Monstrosity

    Now I'm back at this properly I've got questions & I know you guys have answers... What's the most straightforward way of securing a centreline hinge pin in a solid foam core elevator? Bonus points if there's a really foolproof way of getting them perfectly aligned. Centreline hinging allowed...
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    CNC Foam cutter

    They look great! I really like the idea of foam ribs. Are you putting glass or spruce cap strips on em? I had a go at making a vacuum hold down for mine so I wouldn't have to keep putting all the screws in otherwise pristine parts. Be really useful for foam.
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    Matty's Marvelous Modular Monstrosity

    A year and a half since my last post about this thing. Who'd have known having a kid/covid could be so disruptive? I'm going to pick this up like a bad soap who lost the lead actor, replaced him with someone else and just pretended it never happened. The render's the old one FYI...
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    CNC Foam cutter

    I used jedicut which took a lot of work to get right with a .dxf input as it's aimed at rc wing cutting but it does alow you to specify a kerf at each end. The real problem with this was that I only had the 'really long wire' epiphany after milling the moulds for the other tip. Each process has...
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    CNC Foam cutter

    Yeah probably. 36v at about 3a I suspect. The tip is moving half the speed of the root which has a more sensible kerf but is the limiting factor. The great thing about it is you get a really nice firm surface where the foam has melted.
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    CNC Foam cutter

    It's primary use is small, accurate adjustments to delicate equipent
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    CNC Foam cutter

    It finally occurred to me that I could convert the thing to cut cores/moulds of almost any size by having independent towers and a weight tensioned wire. I don't know why it took me two years to think of that but there you go. Here's a 1.8m wingtip upper mould that turned out pretty good first go!
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    Elon Musk being Elon Musk

    I've never thought of freefall parachutists as gliding but I guess they are really.
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    Vacuum bagging do's and donuts

    Next up trying to keep the wrinkles out of these. Should be fun.
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