A word of warning Douglas.
Carbon fiber dust is a very bad substance to get into your lungs. When you cut it with a dremel you should, at a minimum, be wearing a filter that prevents the dust from entering your lungs. At best, you should be doing it in an environment that doesn't leave the dust all over your floor and workbench. Vacuuming the dust off your floor and workbench isn't a good idea either, for obvious reasons.
Anker
At 10:53 AM 1/24/2005, Douglas, Brent wrote:
There's another carbon product you might consider - Jim Marske* sells "Graphlite", a very high modulus carbon (rod, rectangle). I had a scale builder recommend it, and it's pretty great. I bought a roll of it (like working with spring steel), and I've been using it for a couple years now.
Cuts with a dremel, doesn't require any prep before bonding. You could use this in place of your spar, just add a good web and wrap along the length with kevlar or dental floss. Also, since it's so 'unidirectional', it splits very easily with a chisel for smaller spars.
This may not help you here because of the size difference (difficulty in matching to the notches in your ribs), but it's a good thing to keep in mind for later. It's relatively cheap, too - I bought a 100 foot roll for around 80 bucks.
Good luck, Brent
* home built sailplane manufacturer
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Anker Berg-Sonne
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