Sheeting the cores

Once this step is complete, you're almost halfway to a framed VF3!

There are a zillion ways to do this. The only things you really need is a hard flat table that won't bow under a few hundred pounds of weight, and some weights. you need at least 200 lbs for the wings. Various clamps and such are nice for the turtle decks too, just use your imagination here.

Here is the simplest way to sheet a honeycombed foam wing core.

Use a good, low viscosity laminating resin like west systems fast or slow cure.

Use a glue syringe for the honeycombed section.

Lay the core on the skin, and mark where the solid section begins. This is the only area you will apply glue to the skin. Always do the bottom skin first.

Glue in the spars with polyurethane glue. You don't need them more than damp.

When you are ready, mix about 18 grams of resin for the solid section per skin, less is better, but this is aceptable.

using a playing card or something similar, spread the resin on the skin in the marked area. To hedge your bet, next roll the skinn area with a foam roller to get it even and soak up the excess resin.

Using a glue syringe, apply a bead of resin to the honeycombed structure. You shouldn't need more than a 1/16" wide bead. on the LE, TE and Tips, apply 2 beads side by side to ensure adequate bonding. Do NOT get crazy here.

Also add a small bead to the tops of the spars, false rib and hinge line area.

Place the skin on the core carefully. Now flip the core, place it in the bottom shuck and repeat for the top side.

When both skins are in place, install the top shuck and begin weighting the core. Take care to align all corners.

As you apply weight, check the LE and TE with a traight edge to make sure the panel is not bowing under the weight.

200lbs is what I would consider minimum. The more weight you can use, the less glue you have to use. The amount of resin you can get away with would scare you.

Later I will demonstrate a vacuum/ carbn veil technique that I have been using.

Let the cores cure in place for at least 24 hours before removing.