EPP Foam Designs

Food for thought

by Dave Sanders  - Summer 1998

 

Dave has been a PSSA member for over a year now and runs Dave's Aircraft Works.  He comments generally on combat flying experience in the U.S.A. and provides useful knowledge for all interested in utilising the new EPP foam which produces an almost indestructible PSS model.

 

Combat... the mere mention of it sends shivers down the spine of soaring purists.  As has been true over here in the U.S., it would seem there's been a bit of controversy surrounding the subject with you folks in Europe.  There's a bright lining on this cloud though, which I hope to reveal to you here, even if you find the concept of combat an utter sacrilege.

The innovation that made combat flying a practical reality was the use of EPP foam.  The initials 'EPP' stand for Expanded PolyPropylene, which differs significantly from the styrene foams we've been familiar with for years.  The primary difference is its resilience, its essentially a `rubber' foam, meaning it won't dent or mark like regular styrene foams.  This means you can construct parts capable of withstanding tremendous abuse without any structural degradation.

You've probably all been made quite aware of this already, so I won't belabour the details.  Rather, I'd like to explain some ways that EPP can be used outside of the normal `smash and slash' combat environment.

After a few seasons of combat, some of our more adventurous designers began to explore the possibilities of using EPP foam to construct more accurate scale models that had the same sort of durability we had become accustomed to with our combat ships.  Let's face it, after a few muffed landings with a combat ship that incur no damage whatsoever, you're pretty well 'spoiled' - you just can't justify the labour involved in restoring a conventionally constructed aircraft because of one little mistake made on final approach, or the accidental mid­air that happens from time to time. 

NOTE : the planes you see here are NOT intended to be used for combat, although they are quite capable of surviving a happenstance midair or not-so-great landing.  Add to that the fact that they're fairly quick to construct and can give quite convincing scale appearance; just look at the pictures here and judge for yourself!

These aircraft are constructed much like their smaller combat cousins, but all the components have been scaled up to handle the larger loads and stresses involved.  The application of reinforcement taping and covering still remains the same as well, although it's done a little more judiciously to preserve scale appearance.  Some of the examples of EPP foam aircraft you've seen may have looked pretty 'gamey', but after time and experience you begin to develop the skills and techniques necessary to finish EPP with a level of quality that can rival that of conventional construction.  For details on this, I invite you to visit my own Web page as well as other manufacturers to learn the nitty-gritty details, as it would simply occupy too much space here in the newsletter.

My own P-51 D from the Durable Aircraft Models kit.  This plane is a super performer!  People don't believe it's a foamie until I insist that they pinch the wing panel and see that it is indeed made out of rubber!  This example sports a clear canopy and detailed pilot.

I've been an ardent PSS and Scale modeller for over two decades, so I'm no stranger to the things we all know and love; fibreglass, paint, exotic fibre materials, etc... BUT.. when I want to go out and just enjoy the sheer fun of `wringing it out', my EPP scale ships are at the top of the list!  Just a weekend ago, I had the dubious pleasure of executing a split­S a wee bit too low, and sure enough, the aircraft met terra firma with an impact that you could feel transmitted through the bottom of your feet!  What was the damage?  None, if you exclude my ego!  I simply walked down the hill, extracted my still intact aircraft from some of the regions rather tough local flora, and hiked back up for another flight!  Which plane was it?  Take a look at the non­specular blue P-51 D pictured here... THAT is the plane!  This aircraft went in going well in excess of 50 MPH and suffered NO damage other than some small tears in the covering on the bottom of the wing and fuselage.  If it had been a balsa or fibreglass ship, it would have gone home in a trash bag.  Think about that.., a trash bag.  I know you've brought planes home this way yourself, and it's not fun.

I still build in traditional materials, but about the only planes I build that way anymore are my giant scale sailplanes I use in scale competition (I've just recently completed a 1/3 scale MCM CB-15 Crystal - 300 hours and about $3,000.00).  I'm not wedded to any building technique, rather, I have found ways to get maximum pleasure from my hobby time and money by using materials appropriate to the level of detail necessary for a given airframe used in a given capacity.  I'd encourage you not to discount the possibilities of a new construction technology without seriously considering its merits for different uses.  Wouldn't it be more fun to teach a friend or family member to fly with a crash-proof model?  You can obtain an EPP trainer for that person right this very moment!  How about a scale PSS plane for practicing aerobatics?  You can construct one to match your finely finished contest plane in every dimension, then proceed to find its foibles and quirks without risking your showpiece.  How about checking the lift?  Did you ever wonder if there was enough wind to fly your favourite planes but didn't want to risk landing out?  Test the air first with the EPP ship, and you'll have a good idea of what to expect when you throw out your 100 hour, $300.00, scale beauty.

Out here, a happy balance has been struck between all the different flying and construction formats.  Nearly all my clubmates sport a full quiver of traditional scale ships, glass PSS ships, racers and of course, combat ships!  One thing is sure, though.. you always know who the real scale enthusiasts are in a combat match.. the ones flying foamie warbirds!

Another all EPP model by Wade Kloos; his 1/7 scale Supermarine Spitfire.  

This was the model he used to prove the concept of a very scale EPP model.  Experience from this plane went on to be used in his Mustang kit.

I hope this helps you to see the true beauty of EPP foam for uses beyond combat.  Trust me; it could change your life and open new vistas in your scale modelling life... don't fight having a good time!  Life is just too damn short.

One final note.. I'm not simply schilling EPP foam because I make EPP airframes.  I could make a very comfortable living building custom scale aircraft from conventional materials if I chose to.  The fact of the matter is, that this is a technology that just has too many possibilities to discard out of hand.

If you'd like to find out more about really scale EPP models, send me a self-addressed stamped envelope and I'll return a complete list of EPP manufacturers.  At the moment, Durable Aircraft Models is the only company offering exact scale EPP kits, but others, including my own Dave's Aircraft Works, will be offering more models soon.  Write to:­

DAVE'S AIRCRAFT WORKS
34455 Camino El Molino
Capistrano Beach, CA 92624
USA.

For those wishing to obtain more information on a speedy basis from Dave, you can telephone him on:­

(949) 248-2773

or E-mail -  davesaircraftworks@compuserve.com

or visit his web page at:­ www.davesaircraftworks.com

 

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