I am going to make my struts covers from blue foam covered with 3.8 oz fiberglass cloth. I made my hot foam cutter from "e" guitar string, small spring, 1x 4 pine wood for the bow. I am using a old DC transformer from a train set. Here is my bow and I will post photos as I go. I used an ihook and a rivet on the other to hold the string(metal)
Here is the foam. I used heavy speaker wire between transformer and bow. You can use 12 or 14 gauge house wiring
Here is my first cut, I used my leftover lexan from windscreen for pattern, flormica works best. Trick is to move bow slow and don't bend wire, I used a 12 battery for power
My test piece , think it will be ok. Just tuck a little time to cut all the parts. I cut the inside tube with hot wire cutter. Take a little practice to get the right speed
I like to glass them. It make them stiffer than fabric and will not dent. I use west system epoxy, I have made numerous r/c plane molds. I made a 110in long sr71. The trick is to keep it light by using paper towels to dry excess resin off.