Anyways, we learned a lot while constructing our first prototype ribs and we thought we’d share some of our lessons with y’all so you can *hopefully* avoid making the same mistakes.
Lesson #1: The hot wire is not your friend
Right off the bat we struggled cutting our rib profiles out of the XPS foam using our janky home made hot wire cutter.
While many home builders opt to manually draw out their airfoil profile by hand, we decided to CNC mill a stencil out of Medium Density Fiberboard (MDF) to use as a stencil for the hot wire cutter.
This seemed like a great idea at first but when applied, the hot wire was a little too hot and ended up burning the MDF stencil and deforming the foam if not fed at the exact right speed.