Coroplast Construction Techniques.


 RC Plane Construction with Coroplast Sheet
  • What is Coroplast?
  • Coroplast aka Coro-flute or Corrugated Plastic is a material similar in structure to corrugated Cardboard. Made out of Plastic.
  • Working with Coroplast is very simple.
  • Tools Required to work with Coroplast sheets :- Basically a good quality paper cutter with spare blades is the only main tool required.
  • See the bottom pictures to understand marking and cutting coroplast with paper cutter/ other cutting tools.

 



 










  • Of course you should have basic workshop tools for additional work requirements.
  • Suitable glue for Coroplast – Any cyno based glue can be used.(eg:- Flex-Quick, Fevi Quick, Ana bond, Super Glue..etc..).
  • Never use excess glue to paste Coroplast sheets. If you use excess glue, the sheet will not stick together perfectly, always use as small spots or lines.
  • Reinforcements:- You can use strips of Coroplast sheet itself as doublers and stiffeners.
  • When using Coroplast sheet strips as stiffeners and doublers make sure that when you glue them together the direction of flutes should be perpendicular to each other, when you make strips cut them accordingly.
  • Balsa strips and sheets of different thickness are the best to use as stiffeners and doublers.
  • To give strength to horizontal/ vertical stabilizers and wherever required you can insert carbon fiber tube / cycle spokes / bamboo sticks through the flutes.
  • Properly light up your work area, to see the flute lines.
  • When you start working on a model, make sure you have all of the supplies you need for your plane. 
  • Keep fresh blades . Also you should have a proper cutting board, a plywood board of sufficient size can be used as replacement for  a professional cutting board.
  • Terminology: Flute: The long tubes that seemingly seem to run down the length of the Coroplast sheet.
  • Opening a Flute: (see the diagram below).


  • While cutting the sheets of coroplast, please use a Ruler.
  • See the picture below to understand the neutral setting of Ailrons.


  •  See the picture below to understand the cutting of control surface edge (ailron / elevator) to avoid fluttering.



  •  Hinging methods for control surfaces.





  • If you should want to use different coloured flaps and fins, then here's where the hinge tape or hinges come into play.
  • Only tape ONE side of the control surface to avoid stiffness.

 





  • Wee will see the construction of a wing using coroplast sheets.
  • This pictures are to understand the folding technique used.
  • Folding along the flute line is very easy.
  • But many times you have to fold the sheet across the flute lines, mark a line where you want to fold, crease this line with a blunt tool using a scale as guide. you will crease across the flutes.
  • See the picture below for better under standing.

    •  Making of a 5 deg dihidral wing for a trainer airplane. 










    • Reinforcements
    • See the pictures below to understand reinforcement methods.
     Balsa wood strips usage as stiffeners and doublers.

     Usage of cycle spokes to strengthen tailplane.


     Wing mounting plate.
     Battery bay and motor mount.
     LG Mount
     Servo tray
    CF Tubes inserted through flutes.
     Wing spars using coroplast strips and balsa wood

    Wing attachment for mid wing models
    Ply wood reinforcement for servo and battery bay
     Reinforcement for main LG using bamboo sticks.

    • Coroplast construction is one of the easiest way to do model airplanes.
    • In this you have to make the shapes with cutting, bending and pasting, sanding to shape is not possible.
    • So detailed scale modelling is difficult.
    • Another drawback is the weight factor, coroplast is heavier than Balsa wood, Depron and HD Foam, so light weight modelling is difficult.
    • In spite of all the disadvantages, coroplast is the cheapest construction material avialiable locally.
    • You can start your RC plane construction as a hobby with minimum investment by using coroplast sheets.
    • Repair is very easy after crashes and if it is beyond repair also, you are not going to loose much money.
    • So I advise you to begin with coroplast models.
    • When you master it go for full balsa  , depron or HD thermocol models.
    See the SPAD LC-40 Basic Trainer (Electric) - Coroplast Construction.