>Why not just use a mandrel and CF braided tubing?
>That should give you 45-degree fiber orientation, 
>a very nice outer surface, and no need for mold building 
>or bagging.  Or am I missing some important fact?

This is ideal for a torque tube, but not a tailboom.
The 45 degree tube will have only 15% of the bending stiffness
and even less bending strangth as a unidirectional tube 
of the same weight. 

One compromise solution is to use an oversize braided tubing
like the 1.5" circumference stuff from CST.  When stretched
out to neck it down to the 1" mandrel, it will have roughly
30 degree fibers.  This will have 40% of the bending
stiffness of the uni tube.

- Mark
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