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Old Mar 06, 2012, 03:39 PM
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Father of Fr3aK, DLG Pilot
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USA, OH, Worthington
Joined May 2002
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Rohacell can be purchased down to fractions of a mm.

I used to hand-shape all cores. If doing it with vacuum, you want to use 6mm lower density XPS like 15psi pink or blue and bag it into each side. Hotwire / sand to the parting plane and add some splooge around the LE/TE then compress. If you sand the cores flush, cover the parting plane with tape or something else thin so it protects from scratching and leaves the foam a couple thousandths proud.

Hotwiring leaves the foam a couple thousandths shallow, which must be filled with a light splooge mix. Kerf is evil in this situation.
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