Here's the profile of our foam core.
We used a section of carbon with threaded rivet inserts to support the wing's endplates.
Wrapping the first layer of carbon fiber onto the wing.
We applied the second layer in the same way.
We used a roller to evenly distribute the epoxy resin.
The wing element (and a copy we made as a proof of concept) are curing in a vacuum bag setup.
This picture looks much like the previous, but now 48 hours have elapsed and the epoxy in the wing is cured.
Matt peels the layer of vacuum bagging off the element. The untrimmed piece weighs just 3.5 pounds and exceptionally strong.
We're welding up aluminum mounts to hook the wing to our chassis.
Our next major project for our LeGrand is the production of a new main wing element. We’re aiming for around 6 square feet of wing for the rear array—we’re allowed 8 total square feet. We figure the best way to do that is to make a 12x55-inch main element and add a secondary (and possibly tertiary) element to bring the total chord into the 15-inch range.
We found a source for an inexpensive foam wing core, and we’re using composites from The Composite Store. Look for more information on this process in an upcoming GRM magazine article; the pictures here are an overview of the project. We performed the work in the materials lab for the Aviation Maintenance Science department of Embry Riddle Aeronautical University, but the work could be duplicated in any area with large horizontal surfaces.
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