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Composite spar in solid foam core

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rtfm

Well-Known Member
Joined
Jan 3, 2008
Messages
3,989
Location
Auckland, New Zealand
Hi,
I have been worrying this question for some time, and have still not settled on a simple/robust construction method. So advice is being sought...

I had considered building my spar according to the Jim Marske method. i.e. Build a U-shaped channel, lay a layer of glass, then lay graphlite rods in the corners of the U, and finally cover with another layer of glass. Then vacuum bag.

So far so good, but then comes the tricky part - marrying this spar to the foam wing. Do I shape the foam first, cut the foam, insert the spar and bond together? Seems like a recipe for mis-alignment to me. Not even to mention the fact that the foam can't be shaped/hotwired as a single piece. There is going to be a half-dozen pieces all bonded together. I just KNOW this is going to end in tears...

How do other builders do it and keep everything aligned?

Comments welcome.

Regards,
Duncan
 
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