Leading Edge Templates

2025-07-22

Over the past weeks I have been working on the templates to cut the leading edge molds out of XPS foam. I decided to do both the vertical and horizontal stabilizer leading edges in carbon.

Template Design

I designed the templates using FreeCAD based on the profiles from the plans. Preparation of the templates for the vertical stabilizer was a bit more involved — well, at least for me. It took several attempts to figure out how to project the profiles onto a plane at an angle. The vertical stabilizer is of course tilted, so when designing a template where the upper and lower parts are aligned with the leading edge, the profile is projected onto a different plane.

3D Prints to Aluminium

Cutting the aluminium template.
Cutting the aluminium template.

Results

Both hotwire cuts done. Horizontal stabilizer to the left, vertical stabilizer to the right.
Both hotwire cuts done. Horizontal stabilizer to the left, vertical stabilizer to the right.

Horizontal Stabilizer

Front view.
Front view.
Back view.
Back view.

Vertical Stabilizer

Front view.
Front view.
Back view.
Back view.

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