Router Bench

Hi Folks,
I have spent sometime producing a couple of leading edges for two Flightstreaks, that I built recently. The leading edge on the plan is not available stock, here in the UK. So I glued together a couple of strips of medium balsa (as shown on the plans) and spent quite some time with a bandsaw, razor plane and then sanding block. Lots of balsa shavings and dust, plus a few aches and pains!
I am encouraging some local youngsters to take up control line stunt. I have had a great deal of success with both the youngsters and the 'streaks (FP21 and BBTU) and I now need to build a few more 'streaks. This time with the youngsters eager to help and learn (now isn't that music to our ears! they have been weaned from their computer games!).
I sat looking at my router bench. Now if I made a simple router cutter, say a slotted shaft plus a piece of mild steel cut to the LE contour. This could be sharpened and maybe even case hardened..... I have the workshop facilities so it would not take long to make.... I could then produce the LE's in double quick time. Just right for a bunch of learners prone to crash often!
Its such an obvious idea, I am sure that someone must have tried it! Any snags or things to look out for, before I make piles of balsa shavings at a much higher rate?

Thanks in advance,

Andrew.

Why not first try a commercially-available router bit? See:

http://mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/bt_bull.html

I personally don't believe the Flite Streak is the best choice for a Stunt Trainer. It just isn't sufficiently durable for the ground-pounding it will take. I'd suggest you buy or adapt the U-key planform as your Stunt Trainer, as it's exceptionally durable, and can be used as a basic trainer through Intermediate Aerobatics with adjustment to the elevator deflection and noseweight. It's available from Jim Pearson - - See: ModelWings (at) aol (dot) com, and is available in 3 sizes, the 15, 35, and 40, and can go from box to field in as little as 12 hours; most of that time being for glue curing.

Good luck, and congratulations on your success with the kids!

Thumbnail bits cut a profile that is very close to half of a leading edge cross section. You could make a leading edge by making two passes. You would have to make a jig (custom fence) to guide it for the 2nd pass.

Here is one source, there are many others..

http://eagleamerica.com/thumbnail/p/174-2005/

Allan Perret

Hi Ralph,
You may be right about the Flitestreak not being a good first trainer. The youngsters fly over fairly long grass, so its not as bad as it may appear! The initial flight training is done with an old AM design called Pedro. This has an aluminium fuselage, made many years ago, by my father, It even has a formed aluminium "cap" on the leading edge. The mods to the standard design, were the result of my father getting fed up with profiles that don't bounce! It doesn't have much in the way of a stunt performance, but it has taught many people to fly over the years, apart from the tail feathers, it is pretty robust!!! In fact it has lasted 48 years so far!!!
Thanks for the suggestion of commercial router bits, the ones you mention, have a half round profile, which is not a very good match for the Flightstreak LE. This was the main reason that I thought of making a bespoke bit.
I shall probably give it a try over the weekend and report back on the results. The main reason that I posted, was that a lot of my bright ideas tend to go a little pear shaped in the execution! I am sure that someone has tried this idea and I don't want to reinvent the wheel, the commercial LE's are presumably done this way, but with a custom router bit at a custom price!

Regards,

Andrew.