Molded Rotor Blades
Hi Bill,
Welcome back from France. You don't set still very long do you. It just so happens that I now have three molded fiberglass blades as of this evening. I've got to do a little balancing and I may get a chance to try them tomorrow. I have them mounted on a hub and wanted to see if they would spin but didn't have any wind. So, for something different I put on the roller blades and headed down the street. I had them mounted on the end of a two foot board held in front of me. Amazing how hard those blades push when they came up to speed. I can see now why they lift the gyro.
On the negative side, the blades are heavy and the trailing edge doesn't come down to a thin edge. The mold came out pretty good. Bob Godfrey really knows his stuff. He wanted to make the first set out of fiberglass but he said that he could make them out of carbon fiber and they would be a lot lighter and stronger. These were made out of 2 layers, top and bottom, of 6 oz cloth with epoxy. Bob has several ideas for improvement. One is to fill with some type of expanding foam like you suggested but it's not urethane. I don't think we are there yet but gaining.
Phil