>"potting" your servos in a bed of epoxy and microballoons

This is one of my pet peeves. There is no need to glue servos into foam.
I've done it quite a bit with epoxy and hot melt glues but not any more! I
haven't glued servos into a foam combat wing for 6 years!! Really! Planes
spanning from 36 inches to 16 FEET. NO GLUE on the servos.

The secret is to cut proper holes. Square, smooth and sized just a hair
small. THAT'S IT. I've combated planes brutally (well, as close as I can get
to brutally) and the servo holes stayed tight for the life of the planes!
I've done this with many servos, full sized to micro. On many planes that
were bungee launched and the recipients of the dreaded "head-on" collisions.
These planes lasted years and the servos were tight from the first day to
last.

The only reason to glue servos is a sloppy hole in the foam.

Doesn't it seem logical that the union of one inflexible item (servo) to a
very flexible material (foam) will yield STRESS RISERS at the point of union
and respond to impacts VERY differently. The best solution to these is to:
1. Make the surface area smooth, 2. Don't try to make it stationary with
glue.

Bill Swingle


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