May 03 2004


Spars construction with high density inserts at ends for pivots. I used "1034" filleting compound to make the HD inserts but very heavy foam would have been easier. Note: One 4' x 8' 13 mm thick composite panel weighs 18 lbs! Lighter than a 1/4" in. plywood (24 lbs).

Tracing spar on sandwich panel using template:

Cutting parts:

Vacuum bagging 2 thicknesses of sandwich panel for a total of 26mm:

Cutting cavity for High density inserts:

Molds for HD inserts:

HD inserts ready for light sanding: