2.6.0 Filling and Sanding Wings and Winglets

The Process begins. I made up fairly large batches of the epoxy finish material and basically just slathered it on using drywall trowels. Sanding involves the use of multiple tools including: 6” orbital sander; 4” orbital sander; palm sander; sanding blocks; dust collection system; 16” long sanding block and 6” long sanding block (these both hook up to the dust collection system) and a lot of arm exercise! Oh yeah, don’t forget the use of a good dust mask. By the time I finished sanding for the day, I was entirely covered in white powder.  You DO NOT want to breath that stuff in since it contains not only epoxy, but microscopic pieces of glass. It’s nasty stuff!

The underlying fiberglass needs to be smoothed out and "finished". This is the beginning of that process on the upper side of the left wing. I use Velocipoxy "Micro-balloons" here to fill in the fiberglass in preparation for an epoxy primer coat to be added later.

The point is not to have a perfectly white surface - it’s to have as smooth a surface as possible.

Here's the bottom of the left wing after multiple sandings and fill applications of the epoxy gel coat. It's hard to tell from the photo but at this point the wing surface is about as smooth and level as I can make it. The epoxy primer, to be added later, will finish out the smoothing process.

Here's a photo of the finished surface for the top left wing.

The left wing is finished so now let’s repeat the process for the right wing!

And we start the process all over again for the right wing. This is the first coat for the top side of the wing.

Just a reminder here of what the wing looks like before the primary finish coat is applied.

The top side of the right wing is finished so time to flip the wing over and do the bottom side.

I've started to apply the Velocipoxy + Micro-balloons to the bottom side of the right wing.

Now that both wings have the primary finish coat applied and smoothed out, it’s time to start working on the wing mechanicals. That involves cutting out the ailerons and rudders. Yeah, believe it or not, I just got done finishing these wings and now I need to start cutting them apart! Am I crazy or what? Click here to see the process of constructing the ailerons!


© John Trautschold 2016