[aerohead]

Hello all.This is a follow on to an update on the trailer project I posted over at the Aerodynamics Forum.Al is busy but has promised to help get the photos.Let me get this text up,so you all will know what's going on.----------------------------- I've been fabricating the fairings and using a technique from one of my composite books.It's relatively quick and dirty and can get you in the game in short order.---------------- From any design,a set of patterns are generated which are transferred to something structural.You can use anything you want.I've been using cedar.It's light,dimensionally stable,easy to cut and form.---------- From the photos you'll see a photo-enlargement of a strut section I've transferred to cedar,then cut out,sanded to net shape to create a rib which creates the "base" for the fairing.------------ The next operation is to drill, countersink,and install a 1/4" X 2" carriage bolt,which will anchor the faring to the trailer.----------------- Next,the main vertical spar is glued/clamped/screwed,using carpenter's weatherproof glue and drywall screws.-------------- Same goes for Rib # 2,and Bottom cap (wingtip).----------------- After the superstructure is complete,the whole thing is covered with sections of Styrofoam open cell foam,glued on and held overnight with masking tape.--------------- Next day,you can lose the tape and sand the foam to net shape.I use an 18-inch quick-release sanding board from an automotive finishing supply with #36-grit paper.------------ When your happy with your form,a liberal coat of polyurethane spar varnish will create a barrier shield which will protect the foam from polyester-based body filler and resin and fiberglass which follows after the varnish cures.After completion,the vehicle ( trailer in my case ) is through-drilled,part attached from inside,leaving a clean invisible bond.--------------------- Entire car bodies can be created in this manner.Many human-powered submarine and competition bicycle bodies have been created this way.-------------- Your finished piece can be used directly or used as a male mold(plug) to create a female mold to create a wet layup composite component.------------ Everything can be purchased at the home improvement center.----------- I'll go ahead and post this part and hopefully,photos aren't far behind.