The first pic is a form I made for sanding the sides. It is just a piece of scrap foam. I drew the profile from the plans sheet of the bottom side view on it and cut it with my jigsaw. Then trued it up a little with files. I’d already made a profile out of laminex for using on the sides so it was pretty easy. Then I glued on a bit of 40 grit sandpaper. Really this was from a belt sander as the backing is really tough and lasts a long time. While I work slowly this only took 20 minutes to make. I’ve ended up making a few of these as sanding tools.

It helped a lot for getting the sides consistent along with the template. You need to go carefully or it will dig into the foam being pretty coarse.

The second shot shows that I’ve plugged the bolt holes for the landing gear brackets with foam and a little micro. I just cut circles out of scrap foam with my router about 2″ deep. Then a touch up by hand. I got a really snug fit in the bolt holes that were preciously cut carefully with the dremel before the bolts went in. Some of my best work and no one will see it once I’ve glassed the outside of the fuselage!

3rd shot is the curved bottom. Remembering that my foam was 2″ not 1.6″ thick I was able to curve it slightly more. Probably no one will see it or notice but I will have a stronger floor for any big passengers!

Sanding form

Side plugs

Profile