Making an airplane of balsa and have already named it F.F.2.E(Free.Flight.to.Electronic)
Will post pics of the F.F.2.E and what ever details possible as i build along .it is difficult for me to build and make videos or take pic while building im not good at it :banghead: also being a very lite build have to becareful parts break easily,but will try my best,as many have asked me.
The F.F.2.E plane specs will be
Wing span- 25"
Fuse -21.5"
Weight up to - 16grams
Electronics- salvaged from the RTF mini vapor ,horizon hobby
Material - will post as I build along with pictures
My last plane
https://www.rcindia.org/electric-planes/micro-slow-flyer-the-balsa-tortise/?topicseen
Had broken so this build will be similar, with a few changes in the plan.
This is the F.F.2.E plan.
Sorry to be untidy but this is the best I can draw :giggle: so bare with me and go with the flow :rofl:
Started with the fuse
Fuselage is 21.5"
Detachable into 2 parts 12" and 9.5"
1mm sheet of balsa was taken. Sheet Cut into 2cm x 21.5".this was then sanded down like a thin paper,when held under light could actually see light through made it as thin as possible.
It was then made wet under the tap with normal water and wrapped around a balsa dowel around 4mm dia balsa dowel,u can use anything to get the shape.once carefully rolled around the dowel I tied it with sewing thread and left it to dry.
Link to video of the fuse added in post #3 below
https://youtube.com/shorts/N7iGlq-3Gn8?si=sgG48fiseA-CHBDY
Quote from: romanxdsouza on September 05, 2025, 03:05:23 PMStarted with the fuse
Fuselage is 21.5"
Detachable into 2 parts 12" and 9.5"
1mm sheet of balsa was taken. Sheet Cut into 2cm x 21.5".this was then sanded down like a thin paper,when held under light could actually see light through made it as thin as possible.
It was then made wet under the tap with normal water and wrapped around a balsa dowel around 4mm dia balsa dowel,u can use anything to get the shape.once carefully rolled around the dowel I tied it with sewing thread and left it to dry.
Link to video of the fuse added in post #3 below
After this is done https://youtube.com/shorts/N7iGlq-3Gn8?si=sgG48fiseA-CHBDY
it takes a roll shape , then i glued it.used minimum glue as possible.can glue it while the thread is on it too will be easier .
Use this process to glue with a pin
https://youtube.com/shorts/rIIiKngV3fU?si=4w3E_vqtkOO9YvaO
See post #9
once all gluing is done cut it into 2 parts.to make a Detachable hollow fuse.12inch and 9.5inch
The fuse can be made in 1piece,but since I want to keep it safe in a box I made it in 2 parts.
The 12inch fuse will have the wing post sit on it and the 9.5inch will have the tail.and rudder(detchable) on it.in the
12inch piece i put a piece of 1inch long x 4mm dia balsa inside it , 1/2inch out side the tube 1/2 inch inside the tube ,then tied the inside piece with thread and then glued it ,once dried removed the thread .this is done to make a Detachable joint between both pieces.
Next was time to join both parts of the fuse the 12inch and 9.5inch togethere.
So the 9.5inch fuse was put over the dowel of the 12inch fuse.tied both with thread and then glued.was very careful here as the 9.5inch fuse should not get glued to the 12inch fuse..I think pics would explain better
Detachable fuse is now ready.
Anyone has questions so far about the fuse.please ask now while its fresh in my mind.
Ohhh about gluing.took a used tablet cover pour some drops of superglue(fevikwik) into it and used a pin to carry glue to the balsa joints.be as lite as possible we need a good AUW.u can use any method u like key is to use less glue as possible.
Moving to the ribs for the wing and the elevator,took a sheet of 1mm balsa and sliced 1.5mm long strips of it(1mmx1.5mm).then cut them to 7inch long.(apologise cant take video and build together,hope pics help)
So these pieces will be used for the wing and elevator.cut a few extra as some may break in the process.
we need under cambered wings so we need curved ribs of 2cm(drawing in pic below) ,to get a curve on these ribs soak the 7inch pieces well under running water .arrange them well & tie them with thread and stick to a vessel with cello tape nice and firm and tight.(pics may help understand)
Then filled water in the vessel and made the water hot.now and then keep pressing the ribs to take shape.once the water boils put of the gas and leave it to cool and wait till the ribs Dry well.
Instead of vessel you can use your own imagination and try something else .i prefer it this way.Then remove the ribs once dried.
Note:don't have to be accurate on the ribs as long as they are curved all we need is good curve ribs so 2cm or less is ok.
Ribs are ready.
Now I need a break...chaiiiii
Wing post for wings LE & TE
To attach the wing to the LE and TE of the wing posts And the left wing to right wing(as the wings are detachable) .I used ear buds.
EAR BUD
I Cut the ear buds 6mm x 2pcs(for posts) which will attach the full wing to the post
EAR BUD
And i cut 1cm x 2pcs Ear bud (which will be used later for joining the left and ringht wings ,as they are detachable) POST #13
BALSA
Then cut balsa sticks 2mm x2mm and 10cm long ,2pieces for LE & TE these are the posts(pics attached)
BALSA
Also cut 2mm x 2mm and 2cm long balsa stick for attaching the left and right wing later.(you can skip this if you plan to make a 1piece full wing mine is Detachable left and right wing)
I Then took the 10cm balsa stick and sliced it with a sharp blade one side just enough to fit the 6mm Ear bud(pic attached).this fit should not be to tight no to loose.these are the wing posts te and le.
The other 2cm balsa stick do the same till it fits the 1cm ear buds well. So 1cm of the stick should fit in the ear bud(this will be used later to join wings)pic in POST #13
Below pics are of the wing post for the wings LE and TE
Below pics are for joining the left and right wing I will need them later
Below is a drawing of what I have in mind for the fuse.will have to finalise it as per CG required.according will move things around.not an artist so you have to try and understand :giggle: :giggle:
Anyone reading this thread and is intrested in slowflyer and micro airplane have a peep here at these two links
https://www.rcindia.org/electric-planes/successfully-flown-micro-airplane-thread-only/msg154372/#msg154372
https://www.rcindia.org/electric-planes/show-off-your-scratch-built-slow-pace-slow-flying-airplane-only-(with-rules)here/msg152509/#msg152509
Following the plans I drew on post #14 for the wing posts.
LE WING Post is attached to fuse,use a pin to gently pierce a hole through the fuse up and down,and push the 10cm fuse(make sure its straight and in the center of the fuse up and down and a tight fit and then glue and cut the extra potion of the post below the fuse.using the measurments as per the plan (POST #14)
Post details in pics below tired tying :giggle:..any questions leave a comment.thats it for today 8-)
I THEN FINISHED OF THE FROUNT OF THE FUSE(12INCH)I PUT THE TE WING POST AND ALSO PUT ELECTRONICS ON IT.
The TE post was put the same way like the LE wing post(post#16) since i know the wing cord as per my plan is 6.5inch.so from the LE post i left 6.5inch space and put the TE wing post same(TE wing post can also be put later after wings done so you get a good fit. but since I've built before I directly put the LE wing post) the frount fuse was ready then went ahead and put electronics on it.started by puting the motor to the fuse then the brick(rx)
PROP & MOTOR:(from the mini vapor horizon hobby rtf airplane) the fuse frount where I planed to put the motor bent a bit so added a 2mm x2mm balsa stick under the gear box and sanded it down a bit.gave the motor very little down angle to the motor around 2mm and 2mm to the right. (You could say slight angle downwards and rightward at 1-2 degrees each.)the gear box was tied with thread ,then angles degrees were adjusted and then put glue on the thread. Once the motor is done i added the brick.
BRICK(RX): (from the mini vapor horizon hobby rtf airplane) place the brick in the center of the fuse tied it with thread and put glue on the thread.will be using only the right linear servo for rudder.as this will be a 2channel airplane with NO ELEVATOR.(this saves weight too)
Below pics of the TE post
Motor and brick pics
Some more pics to make things clear.
my 12ich frount part of the fuse is ready
Frount view and back view of the 12inch fuse.both wing post in line with eachother And straight
The plan of the rudder is ready
RUDDER
I drew the plan and stuck cello tape on the plan at the spots where i will be putting glue on the balsa joints ,so that the balsa doent stick to the paper.(pic attached circled in orange)
You can even laminated the plan would be easier than putting cello tape.
NOTE: I used 2mm x 2mm balsa here and not 1mm as drawn in plan.(later I will slice of the balsa where ever possible to reduce weight )
to get these bends on the rudder frame. I need to mark were I will be bending the balsa with a pen and then gently bend the balsa to take shape of the rudder.i used the cheap blades (not the sharp side). be gentle do not break the bend as we want to use minum broken joint and glue so the plane is lite and strong.once bending the balsa is done use paper tape to secure it in place on the plan .then I just put glue at the bend with a pin.(remember key is to reduce as much as weight posible)
Im Trying to make a video while making the rudder. the same process will be used to make the wings.its hard to make videos while building i need a camera man...
There we go a small clip of how to bend the balsa to take shape .
This is the rudder https://youtube.com/shorts/8mVDbCJG0wo?si=R9Vcj2ni_gpx19ag
Here is a video clip of how I use glue.
The bent parts are all glued
https://youtube.com/shorts/rIIiKngV3fU?si=4w3E_vqtkOO9YvaO
This process I used in post # 4 as well and all placed where glue needed .
Rudder removed from the plan.be gentle while removing the paper tape off
https://youtube.com/shorts/eeZDav-v7mg?si=SbEhHxYf0c67onxd
WING COVERING:MATERIAL USED IS THE LAMINATE ON THE BROWN BOOK COVER.
PROCESS:take a vessel fill it half with water,crumple the brown paper and put in the water the paper side down and laminate side up.push the paper in the water.then put on the gas and let the water boil for 15mins.
After 15mins peel of the plastic from the paper and there we have are wing covering.
Remove the paper throw it and let the plastic sit in the same water till it cools.
After it's cools remove the plastic and rub off all the extra glue from it under tap water.make sure no glue on it..put it under a light and check ,once all glue removed we can dry and use it.
My wing,elevator and rudder covering is prepared
The plastic is now cut as much as needed for the rudder and flattened on a table and corner are stuck with paper tape.stick the plastic well nice and flat.
Next I used fevi bond on the rudder to glue the rudder to the plastic.sorry I tried video but could not manage :banghead: was difficult to shoot with phone in one hand and glue and this glue is very tacky so can't take video.
U can practice on a few scrap balsa sticks before doing this.
Press the rudder on the plastic well so that the glue catches it well.
Next remove the paper tapes.and then use a fresh new blade to get good cuts and cut the rudder off the plastic. normally at the end i slice of any extra plastic or balsa to get it lite.
Super ! thanks for sharing this wonderful step by step building. Bravo! :hatsoff:
@romanxdsouza,
Care: 2 of the videos are private!
Using empty blister pack for glue is a great idea.
What glue? CA?
I tried a syringe with CA, but it often squirts.
And clogs very soon.
Quote from: K K Iyer on September 07, 2025, 06:37:48 PM@romanxdsouza,
Care: 2 of the videos are private!
Using empty blister pack for glue is a great idea.
What glue? CA?
I tried a syringe with CA, but it often squirts.
And clogs very soon.
Oops now check sir the videos.CA fevi kwik sir.sasta and tikaoo :giggle: even flex kwik will do..have a look at post#9
Moving to getting the rudder to the fuse.
Drawing below
I call that a spacer not sure what is the term used(if anyone knows let me know).its basicly used to lift the rudder up so it doesn't touch the elevator.
Here u see the 1mm carbon road
Next the control horn ,I used the minivapor control horn,u can uses any control horn(use your imagination here :giggle: ) basicly control horn has to be put in this location so u get more throw on the rudder.u can put it throu the carbon rod or into the rudder.i put it threw the carbon rod
Here u can see how it's pushed thru the carbon rod .I have even made control horns with sim card outside cover just cut it to a control horn shape make a pin hot and make a hole through it and u have a horn 😄
Spacer is put below the horn(is a part i took from the mini vapor). You can even just roll thread to make a kind of a ball and glue the thread .
Next will do the elevator(plan below in pic) and then work on the plan for the 9.5inch fuse on which the elevator and rudder will sit.(still working on it)
I went ahead and built the elevator and glued it to the 9.5inch fuse .sorry it's hard for me to take videos while using glue so have only pics of the elevator .however the concept of the elevator frame is the same as the rudder (post 22# and post# 23)only difference is here u add 3 ribs (drawing in post #39)which are glued to the LE and TE of the elevator .notice the elevators TE is 1cm high .lifted up with some balsa pieces.this will give me lift and I'll not need a elevator channel
Note: the elevator cords are not curved refer to post #39,the entire frame is made like the rudder.then the ribs just glued.as per plan
This is how it should look.the LE and TE of the elevator should be straight once glued on the fuse.TE 1CM HIGH
The hollow part of the foward and the aft of the fuse is covered sand down a balsa sheet as much as u can and just glue it to the hollow fuse end.
Next I will be putting the Detachable rudder to the fuse..3inch from the start of the 9.5inch fuse.(marked in red)
In post#34 the carbon rod below the space will be pierced Into the fuse
Mark 3inches from the start of the 9.5fuse with a pen ( post 43#) shouks be exactly in the centre of the fuse.then with a pin pierce the fuse up and down gently.let the pin pass through both sides of the fuse.here you need a good eye to make sure the rudder is straight,at a 90degree angle as as well and straight with the elevator center rib.after holes made I used these small black plastic(from the mini vapor) with a hole for the 1mm rudders carbon rod to go through.this is needed so the rudder sits in straight at an 90° angle.(has to be put)u can use micro servo horns or anything like the phone sim card plastic just heat a pin and make a hole in it.tie with thread and glue
This is how it all works with the rudder.
Red line..control horn
Yellow line ..spacer to lift rudder above elvator
Green line..to support the carbon road in the fuse
Orange line..is a support to hold the rudder..when needed to remove the rudder I just remove it off and the rudder come out of the fuse
Detachable Rudder into the fuse
My rudder is all set
Here is the completed detachable fuse and Detachable rudder.all parts were rounded with a sharp blade ,weight was reduces by slicing blasa where ever possible(have to be very carefully here if u can't mange leave it later if plane turns heavy then u can try) the best part was this was easy to video. :giggle: :giggle:
https://youtube.com/shorts/uevettfeako?si=GaQOdFmsaWDv_YhV
Note:forgot to mention velcro was added in post #19 for the 1s battery 70mah .as per my COG judgment..no big deal can be moved around
The wing is also datchable from the center below is my plan for the left and right wing.to see the details closely for easy understanding.
I have gone ahead and built the detachable wing already , dint want to take a chance with video as its not easy for me to build and shoot.also handling phone and doing it :banghead:
But I Will try and add pics as and when I can, I think that should help.if any questions do ask on this thread not on private message.this could help others as well.as well as members could give there inputs and I could learn too.
NOTE: the wings are built the same way as the elevator. Do see the plan closely ON POST#49
STEP 1: BUILD THE WING FRAME( DO 1 WING FIRST EITHER LEFT OR RIGHT)
DRAW THE PLAN AND FOLLOW THE SAME PROCESS AS RUDDER post # 21 22,23
FOR THE FRAME OF THE WING(PIC ATTACHED)I USED 1.5MM BALSA SHEET ,1.5MM X 1.5MM WAS USED
NOTE: PUTTING THE PLASTIC LAMINATE TO THE WING (wing covering)IS NOT SAME AS THE RUDDER.
.(if you can manage building and shooting a video with a phone :bow: :bow:
NOTE:THE ARROWS MARKED ON THE PLAN that stick will be removed to reduce weight.as we will have a rib sit on it.so I removed it later.
STEP 2: GLUE THE RIBS .once glued follow post#24 with blade remove the wing..and the skeleton will be ready
Next the parts to attach the left and right wing in the centre (ear bud,balsa stick)Post #12 ,#13(pic attached below)was tied with thread and glued.on the wings TE and LE under the center rib of the wings.
will post more pics and details..soon
TO BE CONTINUED........... :thumbsup: :thumbsup: :thumbsup:
NeXt joining the stick and ear bud in post53 to the left and right wing
STICK
This sticks are then joined to the RIGHT WING (le and te)underneath
EAR BUDs
Are joined to the left wing le and te (underneath)
Process: start with the ear buds 1st .tie the bud to the LEFT WING (te and le)with thread.do not stick with glue yet as u may have to adjust it later.
Next put the stick inside the ear bud.
Now u get the right wing and tie the stick to the the RIGHT WINGs le and te(half the stick only to be tied)pic attached
Next make sure that the left and ring wing is aligned nice and straight(the full wings le and te) A little space between the ribs is fine.
Then with a pin add glue to the thread only so much that ear bud and stick ..are
Glued to the stick
(Note the stick should not get glued to the ear bud)
Next remove the wings from the joints and then glue the stick and BUD
(Note tieing the ear bud and stick on the wings side of the le and te rather than underneath is easier.)
The earbud for the post is attached later.
View from beneath(ear bud for posts later)
Once every thing firm and aligned you can gently remove the stick under the rib.see post#51 ,I've mentioned
Added more pics of stick and ear bud for easy understanding.
Next i add the 6mm x2pcs ear bud pieces(post#12) on the wing to join the wing post.(u might have seen it in the early posts)
This is a bit tricky so will post more details when I next have time..any questions leave a comment .. .but before doing so, read well from post#1 to post#58...your answer may already be in there.
NOTE : IF YOU MAKE A FULL WING THERE WOULD BE NO NEED OF STICK AND EAR BUDS :giggle: :giggle:
My build is made to fit in a small box..and easy transport.
To all reading my posts,need some help.
im Looking for this 8520 coreless motor.any good genuine sources in india to buy from.
i don't need a pack with CCW just ..need CW.
(Please don't use it on this build )
Post #59 continued...the 6mm x2pcs ear buds are tied on the wings LE and TE with thread to give it a nice tight fit (pics attached) at this moment the ear bud is not glued just tied to give it a good fit.same is done for the wing TE.
Then attach both left and right wings in the centre .
Next the wing is place on the LE and TE wing posts(the 6mm Ear bud go into the LE and TE posts on the fuse)pics attached
Now the tricky part ...now u need to put glue to the 6mm earbud which attach to the wing post ,as well as have a good eye to make sure the post are straight at 90degrees as well at the wing is perfectly horizontal .(i use frount view to do this)
also the ear bud on the wings should not stick to the stick on the wings (where they join in the centre of the wing else won't able to detach) this will complete the wing attachment to the fuse
Hope this helps
It's not easy to explain so adding more pics
The F.F.2.E I'd ready .. :salute: :salute:
Fits in a 15" box.. :thumbsup:
To fly all I need to do is attach the wings together, then attach the wings it to the post.
For Electronics i need to insert the control rod to the rx (servo) and to the rudder then the rudder to the fuse.then connect battery(1s 70mah) and fly.
It's all up to weather and a place to fly now.so wish there was some indoor space to fly
A quick peep
https://youtube.com/shorts/AZBWgb9cE1M?si=tuKutaC4-Uhrq6DS