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Old 10-27-2012, 08:22 PM   #135 (permalink)
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My advise:

Make some trial parts to get used to working with these materials. When I started doing this I bought a Rutan kit which was a starter kit with instructions of what worked good for Bert.

For your extension make your foam a bit smaller than you want as it is going to be a male mold and your part will be a bit bigger. Use Super 77 spray glue and glue the composite to the foam. Put the cloth on the bias, it will wrap a lot better. I would remove the bottom and turn it over to do the layup, let gravity be your friend. You can just use some flox to bond the parts together when they are laid up.

In areas that are for attachment points to your sub frame make them stronger with additional composite about an inch smaller than the lower layer so that the force is spread out. Don't make sudden changes in thickness. If you use a cloth peel ply you will have a good surface for doing a secondary layup without sanding.

Good luck
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