Wing bagging part 3

Well after the epoxy has cured , we should now have a fairly rigid wing core with it's tubes and shearweb all integrated with the top and bottom carbon spars.
All the hollows are filled and any high spots sanded, unfortunately minor dings do occur and will show up in the end product , try handle the foam with care.


The two ply end ribs are cut to shape and made to fit over the joiner tube which stands out by a few millimetres. It adds strength if this can be "built in " with the wing skins. I have also glued in two thin aluminium tubes which will be part of the removable wing tips/joiner.



The mylar sheet is cut to the size and outline of the wing, I leave about 3/4cm overlap on the trailing edge. I vaguely recall this is medium tickness mylar 200 micron thick? I think.there is a right hand top and bottom I mark the outside thus with a permanent marker. These will reverse for the other wing.

The mylars are waxed with release wax and polished/buffed off , the mylars are sprayed with a white 2k (only just enough thinners) about 3 passes gives a nice solid white. The mylars are sprayed the same day the first wing is to be layed up, I generally start early in the morning.
Once the paint has flashed off and is touch dry , I put thye mylars down on some news paper and I start cutting the various layers off glass cloth.



The first cloth is layed with the weave running length ways with the span, it is a fine weave 106gr cloth and it is cut to the mylar shapeas a template and left in place on the mylar.




The second cloth on this particular wing is a 163gr cloth which is cut so its weave/strands run at 45 degrees to the wing , this resists twisting of the wing while flying, it has to be done with two pieces and distorts easily , so should not be pulled by the corners at all, this layer is also trimmed to the mylars and left in place at this time.



Now in most biggish wings 4mtr upwards I would lay on a second 163gr at an opposite 45 degree bias, but this is a high aspect ratio wing and I want realistic wing flex and used slighty less carbon tows than normal.
So the next cloth is a 100gr uni-directional carbon cloth which makes up for less tows, this comes with a binding thread and a pink plastic backing film. It is difficult to work with but here goes, I lay it over the mylars , carbon down and then cut it to shape, use really sharp scissors,(or even a roller blade if cutting on a decent work surface) once cut it is carefully layed to one side.
Its now lunch time , after that we start mixing epoxy and then its non stop until one wing is in the bag , you need about 3hrs plus if working alone .
Adding the epoxy in the next post.
Cheers
Mike