Hi Wayne Yes I have given this process a fair amount of thought and I am convinced that if I work carefully (specially since I can have the foam CNC cut), I will end up with a very stiff skin that is pretty fair. The only real filling will be over the spars where there will be a slight depression as per normal. The tanks will take any movement of the skins due to pressure change etc as it will be bonded to the skins via injected foam or other adhesive through drilled holes in the skin. I think the extra effort is well worth getting rid of polystyrene in the wings where there is also fuel.
Regards Dene Collett Avlec Projects cc Builders of award winning aircraft tel:27419560048 cell: 27845805003 Port Elizabeth South Africa
