X-Surfer Plans

Step 2: Trace a scaled projection of the design onto the sheet (fig.5) and cut the form (fig. 6). The dimensions I used can be found in the MS Word document here. Step 3: Use the iron to produce an upward curvature to each wing (dihedral).  The iron temperature should be about 150F or 65C and should slide easily on the foam with minimal sticking. Too much friction between the iron and foam is a sign the iron is too hot. Trace the three lines for each fold to form the 5% chamber in the wing as shown on the MS Word document (fig. 7). Use the iron to thermoform a 5% camber (4th paragraph down) into the sheet, propping the sheet against stacked magazines (Soaring magazine has just the right thickness) to bend the plastic and starting from the folds closest to the leading edge (fig. 8). Start each crease from the wing tip, proceeding towards the middle of the wing and finish with the tip of the iron at the middle of the wing (fig. 9). Do the other leading edge before starting the crease further from the leading edge. Repeat for the other creases further from the leading edge (fig. 10).

fig. 5. Trace design on sheet.

fig. 6. Cut out design.

fig. 9 Use iron point to finish crease.

Fig. 8. Creating chamber.

Fig. 10. Repeat for other creases.

fig. 7. Chamber lines.

Comments or questions? Copyright Phil Rossoni, 3/6/03

Page 1. Home Page 3.