Maker Project · Part Three

Fixed-Wing Build, Part Three

From printed motor mount parts to a rigid first airframe: messy, fast, and very real progress.

Warren Blackwell Foamboard Build · Airframe Integration

Part three is where this project moved from bench electronics to actual aircraft structure. If you are joining in late, start with Part 1 and Part 2.

3D-Printed Motor Mount

I needed to print parts to mount the engine. I found this MakerWorld trainer foamboard printable set, and it was exactly what I needed because it used almost the same parts I have on the bench.

Printing the mount parts for the A2212 setup.
3D printed engine mount parts fresh off the printer
Short print time, clean results.
Brushless motor attached to 3D printed engine mount with bolts
Engine attached using M3 nuts and bolts.

The parts came out great, and the screw holes lined up perfectly. I did discover one bad motor out of the four I bought - the machining was off and the holes were not centered correctly. Not ideal, but manageable.

Late-Night Airframe Sprint

Later that night, I finally took a run at the airframe. I started with the fuselage: one sheet of foam board measured into fourths heightwise, coerced into a long box, and held together with masking tape.

Next, I built one wing by bending a sheet in half, then pushing one edge up to shorten the bottom side and force in a rough curve. Tape did the early structural work. Then I attached that wing to the fuselage with masking tape. One wing deserves another, so wash, rinse, repeat.

After that I cut out a stabilizer, attached it with a simple slat approach, and reinforced it with leftover foam board. That was enough progress for one night.

Foamboard RC airframe assembled with wings and fuselage before rudder installation
First full shape: fuselage, wings, and stabilizer in place.
Airframe with electronics positioned, still missing the rudder
Quick systems check while the structure was still open.

Glue, Reinforcement, and Real Structure

The next day I carved out a rudder and started hot-gluing everything together. This was my first time using a hot glue gun and I genuinely liked it: precise placement, fast curing, and easy cleanup once it cooled.

I laced all the major edges with probably too much glue, especially around the rudder mount, which still feels like the most dubious area. I may insert a rod there for extra strength. While attaching the wings, I spotted what looked like a perfect improvised stiffener and added it. The build has been very ad hoc in the best possible way.

Completed foamboard fixed-wing airframe after gluing and reinforcement
End of assembly pass: surprisingly rigid for a first build.
Walkaround of the completed early airframe. She ain't a beaut, but she's mine!
Raddad MKI foamboard plane with electronics installed on the bench
My dog Poppy kept me company for this portion of the build.

Raddad MKI and What Is Next

By the end of this assembly, the plane felt fairly rigid. I threw it a few times and, lo and behold, it seems she will fly. I christened her the Raddad MKI, after my father's usual handle.

After naming her, I laid out the controls to verify wire length and placement. The next push is refining control surfaces, attaching all controls, and finalizing a robust engine mount solution on the fuselage.

Control layout check before final routing and installation.

Next Build Steps

Refine control surfaces, complete linkage setup, and lock in the engine-to-fuselage mounting approach before final preflight checks.

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