Skip to content

FPV Gate Padding: Current Experience

Published: 21 Aug 2026

Note: This is not a scientific comparison. It reflects our current experience from building and operating FPV racing gates.

Current favorite

Multiple layers of roll-stock PE foam covered with PVC truck-tarpaulin fabric

This combination currently offers the best balance of:

  • low cost
  • easy sourcing and cutting
  • adjustable thickness by adding or removing layers
  • adaptability to different gate shapes
  • a durable, repairable outer skin

At present, approximately 30–40 mm of total padding seems like a sensible target.

PE foam from a roll

We use a PE foam roll approximately 8 mm thick. Rolls around 10 mm thick should work just as well.

Advantages

  • very affordable
  • quick to cut into suitable strips
  • several layers make it easy to achieve the desired thickness
  • considerably cheaper than thick sheets or specialist foams

Disadvantages and experience

Our PE foam performs extremely poorly under prolonged UV exposure. Unprotected areas became so porous that a single propeller touch broke the foam into fine plastic confetti. This creates a correspondingly large amount of plastic waste on the field.

Recommendation: Cover PE foam as completely and light-tight as possible. Based on our experience so far, inexpensive PE foam should not be assumed to have adequate UV resistance.

PVC truck tarpaulin as the outer skin

PVC truck-tarpaulin fabric has worked very well for us as the protective cover.

Advantages

  • durable and abrasion-resistant
  • waterproof
  • protects the foam from UV radiation
  • comparatively inexpensive
  • offcuts can sometimes be sourced cheaply from tarpaulin manufacturers
  • can be heat-welded
  • damage can be repaired easily with welded patches

Disadvantages and experience

  • it takes some practice to process cleanly
  • too much heat can damage the tarpaulin or the foam underneath
  • the cover should not be unnecessarily tight, so the foam can still absorb impacts

A hot-air gun, a suitable welding nozzle and a silicone pressure roller work well for welding. This normally makes adhesive unnecessary.

Hot air and PE foam

PE foam can be carefully softened and shaped with hot air.

This can be useful for:

  • clean ends
  • compressed transitions
  • lightly fixing individual areas in place

The temperature window is narrow. A little too much heat causes the foam to collapse quickly. Always test on offcuts first.

Thick PE/LDPE sheets

Ready-made sheets approximately 30–40 mm thick are an alternative.

Advantages

  • consistent padding thickness
  • little assembly work
  • clearly defined construction

Disadvantages

  • considerably more expensive than thin roll stock
  • large sheets are expensive or difficult to ship
  • less flexible for different gate shapes

For now, multiple layers of PE roll foam therefore seem more attractive to us.

EVA and cross-linked PE foam

These are technically higher-quality alternatives with good impact absorption and durability.

Advantages

  • good mechanical properties
  • in some cases, better ageing and recovery characteristics

Disadvantages

  • considerably more expensive
  • so far, no clear benefit for an FPV gate that justifies the additional cost

PU upholstery foam

Advantages

  • soft
  • good damping
  • sometimes available at low cost

Disadvantages

  • less attractive for permanent outdoor use
  • moisture trapped under the cover can become a problem
  • mechanically less robust than PE-based solutions

Pipe insulation

We already have good long-term experience with pipe insulation.

Advantages

  • some products are highly weather- and age-resistant
  • easy to install when the dimensions are suitable
  • in our previous products, damaged areas tended to tear out in larger pieces instead of disintegrating into fine plastic confetti

Disadvantages

  • large diameters and thick walls become expensive quickly
  • suitable sizes for larger gate structures are difficult to find
  • this makes a complete cube less attractive on price

Pipe insulation nevertheless remains interesting for smaller elements or special areas.

Current recommendation

For a cost-conscious rebuild, we would currently start with this system:

8–10 mm PE foam roll

→ multiple layers up to approximately 30–40 mm of padding

→ completely enclose it in opaque PVC truck-tarpaulin fabric

→ heat-weld the tarpaulin

For us, this is currently the best compromise between:

  • price
  • impact protection
  • availability
  • adaptability
  • repairability

Key lessons

  • Plan for sufficient thickness: Approximately 30–40 mm currently seems more useful than very thin padding.
  • Protect PE foam from UV: Exposed areas can become extremely brittle and produce plastic confetti.
  • The outer skin is critical: PVC tarpaulin protects the foam and takes the actual abrasion.
  • Design for repairability: PVC patches can be welded on quickly.
  • Do not automatically buy the most expensive foam: Specialist materials may perform better, but the benefit may not justify the price for an FPV gate.
  • Test before buying in volume: PE foams that look similar can differ substantially in hardness and durability.

Conclusion

Our current favorite is inexpensive PE roll foam in multiple layers, fully enclosed by heat-welded PVC truck-tarpaulin fabric.

The construction is affordable, flexible and easy to repair. Based on our experience so far, the decisive weakness of inexpensive PE foam is its UV sensitivity. Foam should therefore never be left permanently exposed.