Short Final: Structural Integrity

Gemini Sparkle

Key Takeaways:

  • The author, working in aviation in 1978, discovered homebuilt airplanes and was interested in basic designs using plywood airframes with Styrofoam formers and fabric.
  • He sought opinions from experienced instructors about this particular wood-and-foam construction technique.
  • An instructor graphically expressed his low opinion of the method by crushing a Styrofoam cup and wooden stirrer, implying that such aircraft would similarly disintegrate in a crash.
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My first job in aviation back in 1978 was as an admissions counselor at East Coast Aero Tech, an A&P school in Lexington, Massachusetts (a town you may have heard of). As a freshly certificated private pilot, I discovered the magical world of homebuilt airplanes and quickly joined the Experimental Aircraft Association. At the time, there were a few very basic homebuilt designs that used plywood airframes with Styrofoam formers wrapped in fabric to shape the airfoil, control surfaces and various fillets and a fuselage smoother-outer here and there. I even ordered a set of plans for one of the designs. I think it cost me $25.

One day, I was standing around in the airframe shop area and I asked a few of the old-school instructors what they thought of the wood-and-foam construction technique I had “invested” in. After an awkward pause, one of them took his empty Styrofoam coffee cup, bent his wooden stirrer double and stuck it inside, then dropped it on the floor and crushed it under his shop boot.

He said, “That’s what they look like when they crash,” and walked away.

Mark Phelps

Mark Phelps is a senior editor at AVweb. He is an instrument rated private pilot and former owner of a Grumman American AA1B and a V-tail Bonanza.
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