Here we go
First post! Thanks Toby and welcome everyone!
My idea, as always, is to build it as simple as possible, with no special tools. The idea with below mold is to give a flat surface on the bottom but curved winglets. Testing vacuum:
Created a simple wing mold from 2 Flysurfer Razor Board fins (sorry FS:). Why I made this? To get the perfect and proven foiled side with almost no sanding. Wing will be flat on one side, foiled on top. Easy. Make the mold, wax it, pour epoxy in. Cure. Done.
The yellow one is first run from the mold, and, more importantly, the hot water bend test. Latter about that.
Make sure all carbon is cut:
Placing the sanded wing on a mold exactly in the middle, marking with the pencil on the mold :
The wing must be balanced right, sand off more to get the thickness right and equal weight on each side. The top one is waaay thinner and lighter, will be my second wing, if ever:
Now, the trick to bend the epoxy wing for winglets is using hot water to soften the tips. Cut an plastic bottle on top and leave the wing in hot water for some time. Reverse the wing and that's it. It should be soft enough.
Than goes wrapping the wing with carbon, making sure SS inserts are in exact place. Usual glassing stuff. Except post curing with a silicone blanket (42C, was 12C outside:)
That is it. The front wing is done. After taking it out from a vacuum, cutting the excess carbon, I have a nice wing
The SS inserts are secured with 5 carbon strips underneath, and I never drill the carbon. I think it's way better to disperse the threads with a pen and place insert through that hole. It is a bit tedious process but I am killing some time with DIY anyway
All together 6 layers of carbon, 3 top, 3 bottom (plus 5 strips under SS inserts). I can't bend it. But, torsion not so strong.
Now goes the difficult part, making the wing shine
Enjoy