Schleicher ASH31 4m

[MartinE]

All the wing hot-wire profiles have been cut, smoothed and aluminium tape applied (this allows smooth running of the cutting wire).

I cut a sample to check the profile length & depth.

[MartinE]

Canopy plug has been extended all around, initially with foam followed by a couple of applications of P38 filler.

I've also put together a vacuum box from some bits of shelving I had lying around, the workshop. The top I got online, pre drilled and cut.

Hoover attachment pipe is 40mm waste pipe.

[MartinE]

Canopy plug sanded (250, 400, 600 all wet) & primed.

Smoothed with 600 then light coat of gloss.

[MartinE]

Elevator in the vacuum bag, for the top skin. I meant to take more photos but forgot!

Also in shot is the wing joiner with carbon fibre sleeves, to make the joiner boxes. The joiner was wrapped with polythene bag and waxed. Heat-skrink tape on the outside.

[MartinE]

Note that my vacuum pump is a fish-tank pump, with the internal seals reversed (to suck rather than blow).

Vacuum 0.3bar

[MartinE]

Elevator removed from the bag, with all the Mylar & kitchen paper removed (not fully trimmed).
Not bad - surface has quite a few pin holes, where I didn't get enough resin in, so more work will be needed to fill before painting.

[MartinE]

Wing joiner boxes come off pretty well, again some trimming needed.

[MartinE]

Elevator strengthening;
6mm ply piece for the central section, with holes for screw & dowel

[MartinE]

Now the shear webs;
Pre-cured 106gsm carbon fibre strips (45°), cut to size.

Knife used to cut full depth slots, wavy for the main spar & straight for the rear web. Reson injected into the slots, using a 16guage needle.

[MartinE]

Back to the wing joiner;

The location pins are 5mm carbon fibre, set into pre-drilled/reamed bass wood blocks.