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Old 11-11-2020, 12:34 PM   #51 (permalink)
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hollow

Perhaps some Hexcel composite honeycomb core. The floors of commercial jetliners are constructed this way. Sweet!

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Old 11-11-2020, 04:05 PM   #52 (permalink)
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Yes but it's really pricey and filling the cells is a PITA
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Old 11-11-2020, 04:33 PM   #53 (permalink)
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bonding

At the EAA Fly-in at Oshkosh, in 1997, some of the workshops by Alexander Sport Air spoke simply of using WEST System's epoxy resin for bonding, say, a Skunk Works' wing spar's aluminum tubes, blue, closed-cell Styrofoam, and fiberglass fabrics.
After the initial cure, simply placing the parts in sunlight would be enough to drive the post-cure, full-strength matrix crosslinking, without jeopardizing the foam. No autoclaving was required.
The instructor I had, had trained at ABARIS, near Reno, Nevada, in their advanced composites course which I attended the next year.
My uncle used West Systems to construct his Rutan Varieze.

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