Spars

Wing Home

One of our Canadian Readers Jeff had some questions on the SP-500 wing spars, this page was started mid last year, Word Press allows you to do massive photo drops, Just Drag and Drop from a folder, it gets pictures on the site quick unfortunately they are not in order and have to be manually ordered on the page.

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500′ spool of Graphlite, Initial testing showed the material did need to be de-flashed with sandpaper to give it a tooh for lamination.

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Tapered section rod layout & prep

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De-flashing was accomplished with a DA clamped in 2′ increments for handling.

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some hand sanding was used as well

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Final Dull appearance showing the material has been de-flashed from the manufacturing process.

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rods where shop vacuumed with a brush attachment and cleaned up with Isopropyl Alcohol wipes

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Vacuum bag setup pulling ~26-27 InHg a near full vacuum

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once cured the vacuum bag was removed, the white striped material is the absorbent ply outside of the peel ply.

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top bottom caps are a mirror image and made at the same time, the rotozip splits them in 2.

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another view of the cured caps

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setting up the angle blocks for the “C” layup, they are at angles that match the contour of the airfoil vs. the spar in position to make everything line up.

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Hardie Board trim was used for its dimensional stability and was tack glued to the angle blocks.

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dry fit of the caps, root bolt hard point connection, cores, and under peel ply for the partial molding method used.

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another view of the setup

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since the C return was around 1″ wide it was made integral with the main C layup. gravity did not pop this small section off the mold due to the shorter width.

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another view of the C layup

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top return flange section of the mold is removed, black line is for the trim

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overview shot of the C layup, trimmed up and free from the angle blocks

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this section of the return will be re-worked later on.

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outside corner was routered to 1/4″R

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re-using the angle blocks and some more hardie plank to make the support to laminate the outside of the C layup

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Cloth kits

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Outside C layup in progress, some TP helped adsorb the drippings from getting on the partial molding table

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curing layup

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“Lid” Close out core, insert and peel ply

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dry setup of the partial molding

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layup from the wing tip side

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layup from the root side

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a quick splash mold off some duct tape prepped root lid side. this picks up the exact contours of the hard point beef up trapezoids

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cured and trimmed section for a quick sanity check

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bonding this part to the main C after some careful front to back positioning

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another view showing the contours picked up in the splash opp

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some quick bridge foam inserts for the internal mini ribs

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mini ribs where made from pre made T’s with a 3/8″ core

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all the mini ribs trimmed to length

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dry fit lid section trimmed off the free end used to position the “thickness” of the mini ribs

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over view shot showing all installed mini ribs, they are at the same B.L. as the main wing ribs

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Close up view of the root connection

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