On this page, it is described how to build a plywood airplane model of F-16 Falcon fighter. The airplane model is a fretsaw project and it is designed to learn sawing with a fretsaw and other skills. Since the model is not difficult to make, it is suitable for beginners. The model airplane is not a flying one, but it can be used as a toy. It has a seat for a pilot. On the carriers under wings, two rubber bands can be strained to make the airplane armed.
It is not allowed to use this document or part of it for commercial purposes. The exception is teachers who may use it at their own classes.
We cut parts of the aircraft out of 4 mm thick plywood first. We find patterns of the parts in files that are pointed at by links in figure 1. We print the drawings and transfer the patterns to the plywood. A procedure is described in greater detail in the page Transferring Shapes of Parts to Plywood.
Figure 1: Parts of the Aircraft
In the drawings, each pattern is drawn only once. It is written in brackets, how many parts of each pattern we need to cut out. We need two fuselage sides 5, two wheels 11... We transfer all the patterns to plywood.
We cut all parts out of plywood as precisely as possible. We can find some tips to help us sawing in the page Using of a Fretsaw. After that, we drill holes for a wire in the carriers 12 and hinges 13. Drill diameter should be slightly larger than the diameter of the wire.
Finally, we sand the parts to remove cutting marks.
When we have prepared all the parts, we start gluing. First, the tail 2 is glued into the slot in the wing 1. At the same time, we affix the undercarriage 4. These parts must be perpendicular to each other. Then, we wait for the glue to dry. We must prepare the surface to affix the seat back 3. Therefore, we sand the edge of the wing 1 flat to the corresponding surface on the Tail 2. The surface is colored gray in the Figure 3.
Figure 2: Assembling of the aircraft, step 1
Figure 3: Assembling of the aircraft, step 2
We affix the seatback 3 and both sides 5 of the cabin that hold the seat back in place. The arrow points to the edge of the seat back that must be sanded flat to the bottom side of wings.
Figure 4: Assembling of the aircraft, step 3
Then, we affix the dashboard 7 and floor 6 of the cockpit.
Figure 5: Assembling of the aircraft, step 4
To the floor of the cockpit, the nose 8 is glued and under the aircraft, the motor cover 9 is glued.
Figure 6: Assembling of the aircraft, step 5
Now, the front wheel 10 and main wheels 11 are glued.
Figure 7: Assembling of the aircraft, step 6
We assemble the triggers that consist of hinges 13 and lever 14. We glue the parts together. We must be careful to make both holes in the hinges axial so that the trigger could turn. We wait for the glue to dry. The arrows point to the grooves that are made on both sides of the trigger. To make the grooves, a man who is skilled in working with sharp tools should help. The depth of the groove is one half of the wire diameter.
Figure 8: Assembling of the aircraft, step 7
Before the carriers 12 are affixed, we check that the triggers turn for 90 degrees when they are assembled to the carriers. With Abrasive paper, we could repair the carrier 12 and trigger so that the trigger would turn smoothly.
Figure 9: Assembling of the aircraft, step 8
We paint the aircraft.
At the end, we assemble both triggers. The wire should be bent so that a rubber band would not get stuck.
Figure 10: Assembling of the aircraft, step 9
The aircraft is ready, now. To the carriers under the wings, rubber bands are stretched. When we push to the lever of the trigger, the trigger would turn and the rubber band is fired.
Figure 11: Triggering