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The son wants to comparative study of airfoil designs as a science fair project and he (and I) need a little help.
His plan is to make blades out of balsa, put them on a small remote controlled helo he got a few years ago, place helo on a scale (small enough so the majority of the thrust doesn't fall on the scale) then see which design gives the best lift.
He has found some plans for different designs but I think he could use others. Any websites out there for this?
Also I have NO experience in working with wood models or caving and he has even less. How would you suggest he goes about carving the foils? I was thinking a dremal type tool would work but what kind of blade/head would be needed?
My biggest question is how in the world do you make sure that the shape in the wood is the shape you want?
Any and all help would be great and quickly because I'm sure he's going to be asking me and I'd like to impress him on my vast knowledge of woodworking and airfoil construction.


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My daughter did the same thing to me several years ago. My solution to get the project done, was to show her how to build the fuselages from the expanding foam in a can, (Great Stuff).
We made the basic shape using toilet paper rolls and card board cones. Once the basic foam shape was created the foam carved easily into the proper shape for the fuselage, and surprisingly the foam pores were quite small so it looked good when finished.
While we used balsa wood for the wings and stabilizer, you could build the airfoil shape of the wing the same foam.


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