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Model Aircraft Design and Construction
Using Coroplast® Corrugated Plastic Sheets

Below are some pictures of several different R/C model aircraft constructed from Coroplast® corrugated plastic sheets.  Below the large picture, you will also find a link to the project photos where you can learn more about this unique method of model aircraft construction.  Enjoy the pictures and happy building!

These are the type of planes that can be built using Coroplast® Material.

Click on any image to see the enlarged picture...

"Police Airplane - Revision #4" "Fire Rescue Airplane - Revision #6" "40-Size Pattern Ship" "Corrugated Stealth Flying Wing" "Cardboard High-Wing Trainer"

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My name is Andrew Rosz.  I am an R/C model aircraft enthusiast just like you.  Those of you who know me need not be reminded of the type of planes that I fly.  For the benefit of those who don’t know me, I fly plastic. Corrugated plastic… as found in the popular AirCore® kits among others.  I design all of my own planes from scratch and truly enjoy this unique method of model aircraft design and construction.  Over the past several years, I had been working on perfecting the design of a new lightweight "performance" low-wing corrugated aircraft which has now been completed (see the picture above).  In the process, I have also accumulated over a dozen model aircraft design copyrights, and even a U.S. patent on one of my designs.  I have also authored a book "Basic Flight Instruction" which has become an "Industry Standard" R/C flight instruction program when used in conjunction with a qualified flight instructor which I wholeheartedly recommend to anyone wishing to learn to fly R/C model aircraft both quickly and safely.

And as far back as I can remember, all I have ever flown is corrugated plastic.  Right from the beginning, the thought of taking all those little balsa wood pieces of my plane home after a crash never really did appeal to me.  So instead, I fly plastic.  And from my recent observations, many of you too would also like to fly the lightweight "performance" type of plastic planes as I do… if only you new how to design and build them.  And that’s precisely what this article is all about.

Now this whole idea of the model R/C aircraft hobby has five fundamental elements that will appeal to each one of us differently.  The hobby essentially comprises…

  • The Social Element - This is what any hobby is all about. Without the social element, you simply don’t have much of a hobby.  Accordingly, the R/C model aircraft hobby can be enjoyed even if you do not fly or own a ship of your own.  Just go out to the field and become social!
  • The Building Experience - Some people find joy and happiness in masterfully creating beautiful balsa ships; expertly covered and/or painted and worthy of praise and aesthetic glory.
  • Engine Mechanics - Some people find joy in tinkering with engines and obtain a sense of accomplishment in getting the cheapest and most unreliable engine to run reliably; even if only for a little while.
  • Piloting Ability - Some people seem to never get the hang of flying an R/C aircraft while others diligently practice and constantly strive to become a better pilot with each passing day… But we all seem to keep at it; even if we crash a plane once in a while.
  • Aircraft Design - This element of the hobby will appeal to only a select few individuals as most people in the hobby are content simply building designs created by others.  When we speak of aircraft design, this would include building a plane from scratch without a plan or other reference material.  Aircraft design would also include obtaining the necessary understanding of the many factors and considerations that go into aircraft design and how changing or modification of one or more elements will ultimately affect the performance of the aircraft.  It seems that those who take their piloting ability seriously also seem to have a strong interest and/or an above average understanding of model aircraft design.  Not surprisingly, "Piloting Ability" and "Aircraft Design" seem to go hand in hand and indeed, these two elements of the hobby are what appeal most to me; and perhaps you too.

For years, people have routinely approached me with questions about my plastic aircraft designs and how they could get started designing and building custom plastic corrugated aircraft of their own. Up to this point, I really didn’t have an answer for them as there are only a handful of people located across the U.S. who do what I do… that is; design and build their own custom corrugated plastic planes from scratch.  Indeed, the process is totally unlike a balsa building experience and most dedicated balsa fans seem to have little or no respect for this unique technology.  However, many of you DO have a deep respect for this method of model aircraft design and construction as evidenced by the numerous requests that I have received over the years to build custom corrugated planes for others, and/or to teach others how to do it.  Accordingly and by popular request, I have finally assembled a collection of project photos to help teach you how to do just that… To learn principles of model aircraft design and to incorporate those principles in designing and building a custom corrugated plastic airplane of your own.  Enjoy the  photos and feel free to contact me with any questions and/or feedback that you may have.

~Andrew S. Rosz

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