Step 4: Assembly of foam cores and lay up of shear web


2016-04-04: Moved the fuselage outside and wrapped it in some tarpaulin. I needed the space to be able to move freely around the wing.

Mounted the cores in the jig and microed them together. As several other have discovered the mating surfaces between the cores (FC1, FC2 and FC3) was not absolutely straight despite all efforts to cut in level and 90 degrees. I used a straight edge to be sure that the upper surface was straight, since this is the mating surface to the leading edge cores (FC4 and FC5). The gap is visible in the nect picture. I will simply fill this with dry micro later.

2016-04-18: I routed the wing attach depressions on FC1 using my Dremel and a sharp knife. Using the Dremel with a sanding drum is a quick way to remove foam, but go easy on the speed. Using max speed will result in melting the foam. Run at 1/2 speed and it will be ok. I also cut the notches in the shear web for the hardpoints LWA4 and LWA6.

2016-04-18: Glassed the inside of the depressions with 2 BID.


2016-05-16: I had to wait 4 weeks to continue, since the metal sheet for fabricating W18 (0.016″ alu) was out of stock at ACS. I made an order for all the screws and stuff for ch19 that I was missing, but this little item was in backorder for several weeks. Finally got the shipment and was able to fabricate the little metal cover. However – I do wonder why we couldn’t make this of a couple of plies with BID? Just make a plug and fabricate the cover out of glass would be a very easy task. Well – now it’s done and time to think forward.


2016-06-26: Still another pause. This time domestic duties had to be proritized before the plane. Repainting the house takes time :-).

Finally got to work a full day in the shop. Started with cutting all the glass for the shear web.


2016-06-26: Then I masked off the foam below the shear web to avoid epoxy dripping on the foam.


2018-08-11: Masking the left wing a bit different – using plastic instead of brown paper.


2016-06-26: Finally I glassed the shear web and epoxied the two aluminum parts LWA2 and LWA3 in place, and weighed down according to plans.

2018-08-12: Glassed the shear web on left wing. I discovered that the outboard foam core was a bit curved, so I used to straight boards to force the cores back to the proper shape while the glass is curing.


2016-06-27: Removed the masking tape and paper, used the multi tool to touch up the edges f the shear web in the spar cap depressions. Glued the top cores to the shear web and mounted the front part of the jigs again. Set to cure.


2016-07-10: Cut off the corner of FC4 as per plans.


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