I have a build thread on the "other" website in the classic pattern flying section where I show how I built a .60 size nitro Nutcracker pattern model that weighs only 4 lb 3 oz primed and ready for painting. I experimented with a lot of new techniques but here are some takeaways that led to weight reduction
1) used vacuum bagging for wing and tail cores
2) Used carbon fiber veil between the wing sheeting and the core to add to the bonding strength/quality
3) Sheet the wings using west systems epoxy thinned 30-40%
4) Skin wings with 3/4 oz fiberglass thinned 30% then cover immediately with sig micro balloons. (Cuts down on the need for filling and additional layers of epoxy)
5) Used aerofill as a light weight filler. This is magic.
6) Agree with the glue recommendations in this thread.
Your biggest danger areas in adding needless weight are gluing the sheet cores and fiberglassing the wing/stabs. Don't be averse to thinning the epoxy. My biggest recommendation is to spread epoxy using a west systems foam roller. You cut these to a smaller size and can get 2 per roller. Roll until there is a slight sheen. If the epoxy looks flat or dull add a bit more. Remember you thinned and have room for a dab or two more. The thread referenced above explains all of this.
Good luck
-Ken
Last edited by kdunlap757; 02-12-2021 at 06:37 AM.