Tuesday April 7, 2015. Day 4.
The 4'x8' panels and the 2'x8' panels are epoxied together along the 4:1, 3" long scarf. This makes a panel 6' wide for the rear part of the wing. We use West System epoxy in the shop for just about all laminating, so it's our first choice of bonding agent when we want to make sure it's not going to fail. When working with raw wood edges of plywood or other porous surfaces, apply a sloppy coat of straight wet resin to the wood and watch it soak into the wood grain. If you don't do this first, then most of your resin that you expected to be the gluing force for your joint, will wick into the wood and leave you with a resin starved, weak joint. After waiting about 5 minutes for the resin to saturate the thirsty wood grain, apply a second layer of wet resin. this is the resin that will be bonding the joint together. Be sure to lay down a sheet of polypropylene plastic under your wet working area to catch the resin that will squish out. Resin does not stick to Polyprop. You want to see some squish out, to ensure you have a fully wetted joint. But not too much to be wasteful. Good resin is expensive. Once both halves of the 4:1 taper is wetted, we flip the two pieces together and with a couple of hundred pounds of pressure along the 8' long joint, we left it to fully cure overnight.
Wednesday April 8. Day 5.
The next day, the front nose end of the wing was added on by joining another 4'x8' sheet. We rough cut it 2" oversized to then be scarfed onto the larger main panels.
Applying the West System 3 epoxy resin to both halves of the 4:1 tapered joints. A roll of poly plastic to catch the drips.
The finished pairs of raw wings drying in the paint booth. R2 is sitting in a pile, waiting his turn to be built, so he can take a ride with his best buddy, 3PO, on the back of the Landspeeder. Just not enough time in the day...
We left a couple of inches oversized around the edges of the front nose panel to make sure we had enough wood to get the angles right. Both panels finished out within an 1/8" off the target patterns. So it was just about perfect, without hardly any wasted material. You can see the dark stain area down the middle of the panels where resin squished out of the bottom of the scarf joints. This will be sanded off when we prep the wings.
The T-47 is committed to being at the Dallas Comic Con / Fan Expo on May 29 -31 at the Dallas Convention Center. But we are also talking with the directors of Houston's ComicPalooza about being on display the weekend before that, May 22 - 25 for Memorial Day weekend. We have a count down calendar on the main drawing board in the lunch room to remind us we have a very tight build schedule in front of us.
