Here's a new way to quickly build strong and accurate wings using
conventional bagging techniques.

Take a quick look at this picture of a test cut and assembly:

https://lh6.googleusercontent.com/-g...-50-47_181.jpg

The concept works as follows:

The core is cut upside down with a wire channel and a spar channel cut
out from the bottom of the airfoil. The really important element is that
the spar cutout doesn't penetrate to the top surface, which is kept
pristine.

A spar foam core is cut with a center tube cutout and room for the spar
caps above and below the foam. When assembled. the spar fills the cutout
all the way to the bottom surface.

For bagging I have built a very simple female mold of the top wing
surface from foam covered with glass. The mold is stabilized with a
particle board. The panel dihedral is built into the mold.

Spar and core assembly is done by assembling the spar and placing it in
the core and then bagging them in the mold with the mold inside the bag.

After the spar and core assembly has set they are removed, the skin
layup is done and the whole thing is bagged again for a final time.

The building time is very close to a stressed skin wing, the result is
stronger and lighter and the top surface quality is extremely high
because the mold forces the airfoil into the correct shape.

There is lots of detail, but it works.

Anker

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anker, i plan on attending the pumpkin fly this sunday. will bring spar
tubes and caps. perhaps you will have something for me? pb


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