There are 8 plies required and I decided to go for four lots of two ply laid up on foil first. Its quite a tricky layup because you have to get the right angle of glass nicely set in place without it folding over on itself. There is not a lot of room to play with here.

I found putting the lower half of the 4″ wide piece in first worked best. You need to cut a bit of a nick out where the shear web is too. Then those mixing sticks for positioning tools to help ensure the glass was laid out smoothly. The foil technique, sticks and fingers worked well. Sorry there are no pics during the process, I had epoxy and flox all over my gloves.

Once all 8 plies were down I really covered the blue foam inserts in a lot of flox and then let it ooze out as I pressed them slowly in place. I didn’t spare the flox and it took quite a lot although I did get a fair amount to wipe away too. I think several foam pieces work better than trying to do it all in one, less chance of air voids. There was no micro involved as usually happens with foam on glass. I ensured the flox mix really got into the foam cells before inserting them.

The room was about 26C and I left the heater on overnight and through the next day for cure. Its winter right now and cold outside. Then several hours careful grinding away with the dremel to clean things up ready for the next structural layup after I work out where the rudder bellhorn has to go and what is happening in that lower rudder area.

Glass prep on foil

Foam in place

Clean up after cure