There are several "high risk" features of this aircraft design project. Not the least of which is the wing manufacturing process. I will be making fiberglass male tools and wrapping them with prepreg carbon tow (ribbon). This will create a thin mesh in the shape of the wing which will be covered with plastic film. A spar will add the structural support. The wing tool is made larger than the actual wing to allow for excess material. Tool Edge of Part dimensions here:. http://j.mp/WX9az0
The wing tool was made from CATIA generated sections of the wing which were cut out of thin foam. A balsa spar and trailing edge held it all together while I covered it with strips of packing tape. This created a smooth and stable surface to start adding fiberglass veil plys. 10 plys later the wing is pretty sturdy, fairly smooth, and actually quite light.
Bondo time. For those who don't know the joy of fixing old cars or motorcycles, Bondo is a paste like filler which hardens in about 5 minutes to a wood like hard sand-able surface. If you love sanding, this is your wheelhouse. For me however, I would have worn a bunny suit if I had one. That stuff got everywhere. There was a layer of dust in my garage so thick, it looked like it had snowed.
It was worth the trouble however, as I created a great mold for my wings. I will use my home-made filament winder and resin-ator to get the job done.
Comments
So that was the bondo mess I was talking about. Also, a word to the wise - you can't bondo over styrofoam, it will dissolve leaving you with a smelly sticky, peanut-buttery mess. The firts wing molds were ruined but the second ones used that tape trick, which sealed them in from the fiberglass resin and the bondo. That solved the problem.
Mmmmm peanut butter (why are you not using crunchy???) (why are you coating the wings in peanut butter anyway?