Here are some photos of my progress on the rotors for my full scale quad. This quad design targets a 200 kg gross wt with 4 rotors of 2.5m diameter. It's mot much progress, but if you're interested here are the pics.
Rotor Tip Weights
Layup of leading edge portion of airfoil. Wrapped with 2 layers of 6 oz cloth at 45 deg angle to provide torsional rigidity,
Attaching the rotor tips (shaped wood pieces that rounds the sharp edges to reduce corner stresses on the fiberglass cloth skin.Main foam core placed in position behind the leading edge spar section. Trailing edge is 3/4 x 1/16" aluminum strip with very thin tapered wood strips to give correct taper.
Glassed rotor (tip end). You can see rotor tip cap (wood) and foam core with body filler in areas to smooth the surface.
Flashing of excess fiberglass skin has not been trimmed from trailing edge yet. This glass was wrapped from end to end so as to give strength along the length of the rotor and support the centrifugal loads. Tension in the glass skin is transferred to the inboard tip cap which rests against a composite beam, which in turn is bonded to the FlexElement bearingless hub element.