n this standout episode of MasterClass Season 2, Joshua Orchard welcomes Mark, owner of Old School Model Works (OSMW), for an in-depth conversation on the craft of building balsa model airplanes. From laser-cut precision to essential tools and adhesives, the show offers valuable insight for both seasoned builders and newcomers looking to elevate their scratch-building or kit-building skills.
Inside Old School Model Works: Precision, Passion & Authentic Balsa Craftsmanship
Mark explains that he has operated OSMW for six years, personally handling the design, laser cutting, packaging, and shipping of every kit—with support from his wife. His business focuses on airplanes in the .25–1.20 engine size range, an underserved niche after many major manufacturers left the market.
Using a 90-watt CO₂ laser, Mark demonstrates how proper laser settings prevent burnt edges. Burn marks—commonly seen in poorly cut kits—affect glue adhesion and covering quality. Because OSMW parts are cut cleanly, builders do not need to sand charred edges before assembly.
He also explains kerf, the tiny angled cut produced by the laser, and how he compensates for kerf in CAD design to ensure accurate interlocking parts. This kind of engineering is why his kits are known for exceptional fit.
Copyright is another critical factor. OSMW cannot remake copyrighted kits, nor produce cowls or wheel pants without molds, so many of their designs are based on public-domain plans revisited and modernized.
Digital Manuals & Builder Resources
One highlight of OSMW kits is the digital instruction manuals. These online versions feature high-resolution, full-color photos that allow builders to zoom in on steps that may appear small or unclear in the printed manual. It’s a huge benefit for newer builders learning assembly techniques.
Giveaways & Trivia Fun
Two giveaways added excitement to the episode:
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Laser-cut engine ornament: Won by a viewer who correctly answered that Space Control was the first commercially available proportional RC system.
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Sanding bars (pair): Awarded for answering that Dave Platt designed the aircraft used in the film The Battle of Britain.
Adhesives: What the Pros Use
Mark prefers medium CA for prototyping and thin CA for hinges, while Joshua favors Titebond II for its wood-to-wood bonding strength and longer working time. Epoxy remains the standard for firewalls, landing gear mounts, and any location needing maximum strength.
For hinge installation, the episode lines up perfectly with DU-BRO’s CA Hinges, known for durability and consistent action:
Essential Building Tools (Featuring DU-BRO Favorites)
The hosts review a lineup of essential tools, many of which pair perfectly with DU-BRO’s professional-grade accessories:
1. DU-BRO Sanding Bars
Praised during the show for their inherited Great Planes quality and reliability.
2. DU-BRO T-Pins
Ideal for holding ribs, spars, and sheeting securely on the board.
3. DU-BRO Canopy Scissors
Perfect for cutting clear plastics without cracking—essential for canopies and curves.
Alongside these, the team highlights Japanese pull saws, razor saws, metal rulers, #11 hobby knives, spring clamps, cutting mats, and the OSMW-included 90-degree laser-cut triangle.
A Celebration of Precision Craftsmanship
This MasterClass episode is a deep dive into classic balsa craftsmanship, the science of clean laser cutting, and the importance of using the right tools. With wisdom from Mark and hands-on tips from Joshua, builders walk away inspired—and better equipped—to build straighter, cleaner, and more accurate aircraft.
Whether you're sheeting wings, cutting ribs, trimming canopies, or organizing hardware, pairing OSMW techniques with DU-BRO tools makes the hobby more enjoyable and the results more professional.
