Finished the front wing, or at least as refined as I am going to bother with. I tried it out yesterday, and IT WORKED....stoked. The wings felt smooth, no vibration or noise. They are noticably heavier when carrying foil (I was chicken to carve them as thin as original....once over sanded, can't take it back). The ride felt maybe more "cushioned", maybe due to being thicker....maybe that's good and bad, easier ride but maybe lower performance for speed/turning at high end? Remains to be seen for better wind sessions.
A few thoughts / lessons learned:
-- credit where due: thanks to Jim Stringfellow for the originals I shamelessly copied
-- best main shaping tool is belt sander with 50 grit. For tight spots, a dremel with stone shaping tool. A rasp helped for material removal in some areas too.
-- the metal drill bit for countersinking didn't like the g10 very much. A stone shaping bit with a 45" angle worked much better.
-- same with standard drill bit. It took about 10 tries per hole, drill until it smokes, then wait for it to cool, etc.....got a carbide bit for next time.
-- cutting out wing profile: either jigsaw with carbide blade or dremel with cutting wheel
-- draw out high point on wing, helps with getting right angle on leading edge and trailing edge.
-- have to be really careful on the trailing edge....really easy to go too thin, then you're in trouble.
-- model name: the "Scha-wing". (wayne's world reference, for those who grew up in the 80s in North America)
Bottom line: fun project, was pretty easy to make something that works. And if a half-doofus like me can do it, anyone can.
Next up: find a zeeko spitfire to demo and attempt to copy.