Control horns made from PVC are very light and robust. They can withstand many hours of flight with no degradation in performance. Best of all they are extremely cheap to make, all it requires is a few minutes of your time.
Electrical conduits or trunkings are a good source of inexpensive PVC. It is available from most hardware or electrical supply shops. It is normally sold in 6 foot lengths in a variety of widths and thickness. Generally the thickness of the PVC varies proportionately with the width of the conduit. I use 2 inch PVC conduit which is 1.5mm thick, ideal for foamies.
All you have to do is design your control horn preferably using CAD software. Once you are satisfied with your design, print them onto stickers. Stick them onto a pre-cut length of PVC conduit. Drill the linkage mounting hole together with any lightening holes. Roughly trim the outline with a pair of scissors and file them into the required shape. And voila you have a custom made control horn.
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| CAD drawing showing linkage mounting and lightening holes |
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| Completed 1.5mm thick PVC Control Horn |
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