BRIAN GLACKIN <glackin.br...@...> writes:

> 
> Why cut the whole part at once?
> 
> Model the part, create smaller pieces to cut.
> 
> Assemble the smaller pieces. into original whole.
> 
> finish by hand.  Can't be too hard to finish.
> 
> Allows for smaller work envelope and better tolerances perhaps?


Absolutely! Brian is right.

Mike Arnold, of the Crockett Rocket fame, has a series of videos on how you can
do this without even needing a cnc machine by breaking the 3d shapes into slices
that can be cut very accurately out of foam. All you need is a plotter to print
out accurate templates. The rest is epoxy, fiberglass, diligence, & elbow
grease. A hot wire cutter can be hand operated, or you can use EMC to control a
4 axis hotwire machine, but there are other Windows based hotwire/software
packages that have been in use for years.


Here are the tapes:
http://www.ar-5.com/tapes.html

Web site:
http://www.ar-5.com/

Peter, you say: "Stringers and such would of course
be needd." [sic] 

>From that comment (Hey, we all start out somewhere... right?) I am going to
assume that you don't have any experience building full-scale composite aircraft
structures.

Is this true? 

If so, you might want to look at shelling out some $$ for a proven design so you
can avoid becoming your own test pilot. On the other hand, Martin Hollmann has
an excellent book on test flying for homebuilders ;-)

http://www.aircraftspruce.com/catalog/bvpages/testflying.php


Tom
ps. The first item on my flight checklist: "1st have fun!"





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