When a template is larger than the foam board you're using, Do you join two Boards together before cutting out the template?
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When a template is larger than the foam board you're using, Do you join two Boards together before cutting out the template?

Yes, that is the best way to do it. This trick works well for doing that and for gluing large pieces of the plane together like the wing plates.

Take your two pieces of foam and line them up butted close together along the seam where you want to glue. Run a piece of tape along the entire seam where you want to glue, leaving some extra tape at each end for the glue to squeeze out onto so that you don't glue it to your work table.

Now that you have made a hinge with the tape, open up the other side so that the two edges are exposed, folding it back over the tape hinge. Then run your glue along the edges until you think you have enough, then close the book, pressing the two edges together. Lay it out flat on a flat surface with the tape side of the seam down. Then you can use a scrap piece of foam to "squeegee" off the excess glue and fill the joint. It sometimes helps to put some objects down either side of the glue joint to ensure the foam stays nice and flat and even.

My glue of choice to do this is 5 minute epoxy as you have a little time to get it all smeared on and cleaned up and it dries fairly light and strong. Things like gorilla glue which foam up are probably not good to use as you will make a mess of the joint.

To be extra safe in avoiding gluing anything to your work table, I lay down some wax paper underneath the glue joint as it is easier to remove any wax paper that might stick than trying to pry your glued airplane parts off your work table...(ask me how I learned this the hard way...ops

Hope this helps you. Like I said, I find this technique also works well with long glue joints like joining the wing plate pieces of the plane together.

Just be careful and take your time as you cut through the joint you just made between your two pieces of foam board, if your knife gets stuck in the glue and you pull too hard too fast, you could damage the foam.

Hope this helps you out.


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That technique Scott talked about works the best.
When working with a fast drying glue like hot glue,
it is the only way to get a perfect joint every time.
With 5 minute epoxy, the joint is always clean and tight.
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I just lay both pieces on the ground flat and sometimes put wax paper underneath it. Then I run a nice bead of hot glue along one edge and lay both pieces flat as I join them. With hot glue you only need to hold them together and flat for a short time and I have found the bond to be surprisingly strong, like it's one big piece afterwards. This is the quick and dirty squishy method and I usually do this with two cheap $1 pieces of foamboard. If you are using more expensive depron you may want to practice 1st with some scrape or cheaper foam. I personally, would still use this method with expensive foam, but I am a quick and dirty builder, I love cutting corners and reducing steps to find the simplest solution.
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I tape the two pieces together on one side along the whole crack, open the crack up and fill it with glue. Once it's cooled I take the tape off the one side and BAM, solid joint.
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I'm so lazy and thoughtless I leave the tape on, and heck I even put tape on both sides.
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