The sanding form is filled
with 1 1/2" Trymer 2000 foam. I glued the tree pieces together with
Great Stuff Spray Foam. Weights were added to keep the foam from moving
while the spray foam set up. After drying a 4' sanding block with 50 grit
paper was employed to shape the inside of the airfoil pattern. One layer
of glass was laid in the cavity after filling the foam pores with runny
micro.
After the epoxy cured the
foam/glass was removed from the form. A second Leading edge was made in
the same mold. Both leading edges will be attached to the main spars and
plywood ribs. The foam will be sanded to outside airfoil shape. The trailing
edge, top, and bottom, will be glued in at shaped at the same time. One
layer of fiberglass and peel ply will be added to protect the foam until
the main wings are ready to be glassed. Then the whole wing structure
will be glassed at the same time.