Originally Posted by Tsavah
Interesting project. I will be following progress. Hope to learn more about the molding process.
The molding is the easy part, making the wood jig was the harder part. To be honest the jig was also easy but I've been doing woodworking for 30yrs.
I drew the airfoil on the ends of 2 boards, rough cut them on a table saw by ripping them at different blade angles close to the airfoil shape. Glued them together and sanded my cuts smooth.
I then made my 4 miter cuts at 9 degrees to give myself a 18 degree Dihedral. Used a sliding power miter saw for this, then glued the 3 pieces together.
Lightly tack the Depron wing to the wood jig, and wrap a thick piece of chair cushion foam with Ace bandages and bake in the oven, 225* for around 40min.