RobT
Posts: 674
Joined: 9/29/2003
From: Whitestone, NY, USA
Status: offline
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Ward,
Step by step...
Since I use epoxy, I first assemble all of the sheeting for the part to be bagged, (they guys who use poly glue just tape the sheeting together) As I am setting up the sheeting I am sanding it. This skins get a tape hinge on the trailing edge. Next the "part" with all of the necessary servo rails, tubes etc. is sanded lightly. (wing in this case). I leave this on my secondary bench as I get the bag set up on the primary bench. I put the shuck down on the bench, and the bag on top. I personally seal one end first, but some leave the end open so they can work from both sides. Stuff the bag with breather cloth and release cloth cut at least slightly bigger than the part, and spread the cloth out smoothly over the shuck (but in the bag).
Back to the skins, wipe both the skins and the core with a tach cloth to pull up dust. and spread the epoxy out on the skins. (I put newspaper on the bench) The scrape the epoxy all off. If you see epoxy it is too much. The core goes into the skins, like a sandwich. I put a couple of pieces of tape on the L.E. so nothing slides around. Then slide the sandwich into the bag, close the second side and draw down the vacuum. I place the 2nd shuck down on top of the bag with a bit of weight, but this is not necessary. I feel the hardest parts of the whole thing are 1) Assembling the sheeting 2) making sure the core is lined up with the shuck.
Mark,
While cutting the 6.5" pieces I used a square. It was rare that the small pieces did not fit perfectly with Dennis's 48" pieces. When I found one few pieces of Dennis's sheeting that was not square at the end I just used this as one of the shorter pieces that did not have to be 54.5" long.
Rob
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RE: Extra 300 Prototype #2 - 
