cgrcjet

Here is the wing structure in the jig. After filling it with expandable foam, i trim off the excess and float it out. Being in the drywall business for the last 16 years, i tried using 5 minute hotmud to get the fill i needed. Worked out very well. I thought about using bondo for the fill but the hotmud was much easier to use and does not smell like stinky polyester. I made sure the ply structure was sealed. I just sealed it with the wood glue i used to assemble the structure. The hotmud has moisture in it and i did not want any chance of it warping the ply. I did this over a period of 2 weeks to allow all moisture to evaporate before glassing. I applied 2 layers of 2.4 oz. glass. For less finish sanding, i used paper towels to dab off the excess resin like you would do on an open mold layup. After cure i continued with duratec high build vinylester primer to smooth out any low or high spots. I used a piece of aluminum angle iron with with 120 grit sandpaper attached to get my flat surfaces. I marked the low areas and only sprayed those spots with each pass of primer.

Chris