when building my ailerons,i fit the wood spar to the cutout in the glass&
foam so the wood fit the angle of the shape& flush to the cutout recessing the
inter layer of glass to fit flush with the inner surface of the spar wood.
mine
where diel skins, after a perfect fit was made, i beveled the outer edge all
the way around the outer spar edge at a 45 degree angle to make a 3/16 fillet
area when the spar is installed flush. then i sanded the inner primmeter of
the glass for a good bond & also sanded out the foam core for a fillet area to
fill with flox,then i wet all surfaces with epoxy & fill the sanded areas with
flox, insert the spar flush to squeese into the applied flox & tape over the
spar to the outer surface to hold into place, then fill the outer beveled out
area with flox &squegy folx into the bevel area till full & flush fith the
outer surface. this way it comes out smooth & no faring of glass on the outer
surfaces,slick!
steve jones,n121kr, venice fl
