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In wings intended for bagging, I've long filled
over and under wrapped spars with balsa and spackle. I was never totally
happy with the looks or the strength of the bond between these and the main
layup.
Recently, I stumbled into a better way that really
bonds the layup well over and under the spar.
Here is the gist of the thing:
Quick epoxy, heated to be very thin, is applied in
the recess a few inches at a time. A waxed Mylar strip is quickly rolled
over the epoxy to level it out. When cured enough, the Mylar peels off. The
recess is progressively filled in this manner. When all is well-cured, the epoxy
is scraped with a razor blade to level out any irregularities and to remove
the wax on it. The bagging epoxy will then bond very tenaciously along the
spar.
A page on this with several pix has been added to
the GENIE CD.
I'd be glad to e-mail it on request. Ask for File
3, page 13.
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