Panel Materials

If you are going to be doing any composite cutting, I'd make sure you
use a diamond bit or blade. Carbide works, but diamond will still last
longer. Also, if possible use water when cutting, this keeps the blade
cool and will make it last longer, and keep the dust down. Wet tile
saws work great.

Be sure to wear a mask, carbon fiber can get nasty.

Todd
www.sandwichpanels.org

Brian wrote:

If you really need a thin core you might look at just using a peice of
aircraft plywood.

You can also save a small amount of weight by using 1/8" medium to hard
model shop balsa for the core of a glassfibre panel - that's what
Libelle panels are made from. This may also make the panel easier to
make and to cut openings in than if it was ply. Glue the balsa together
with white wood glue before its final shaping and doing the glassfibre
layup.

If you put one or two layers of 200 gsm (6 oz/sq.yd) glass on either
side of the balsa you should have a good panel. Add a layer of 25 gsm
(3/4 oz/sq.yd) cloth outside the heavier cloth to get a nice, smooth
finish. As others have said, put a decently wide flange (25mm / 1")
round the bottom of the panel to protect your legs. If you make the
flange from all the layers surrounding the balsa that should do the trick.

As others have also said, if the panel is part of the fuselage structure
then buy a blank from the manufacturer.


--
martin@ | Martin Gregorie
gregorie. | Essex, UK
org |