Brief Description: R-HS Tip: Construct Foam Rib and Glass Over
I sourced some extruded polystyrene (not the expanded type that is easily identified by the "compressed" polystyrene balls - extrududed has no little balls) that was recommended to me by a local composite and glass shop. Locally, the product is called "Isoboard" and is generally used for insulation in ceilings. Isoboard cuts and sands very easily so cutting out the rib to close the open end of the HS tip was quick work.
I then checked the fir with it clecoed to the HS and adjusted as necessary. Once I was happy with the fit, I removed the tip from the HS and sanded a concave shape into it to mirror the contour of the elev counter balance skin. I then removed the gel coat from the HS tip wherever I was going to overlap new glass to faciltate a better bond.
I then did two layups of glass but struggle t get the glass to lay flat against the sides (i.e. top and bottom when fitted) of the tip due to the small radius of the join and the fact that it was greater than 90 deg. After may failed attempts to get it to lay flat, I eventualy overed the layup in a piece of plastic and wrapped an elastic band around the edge - this did a great job of keeping the new glass flush against the sides of the original glass.
Rib fitted and sanded to shape - gel coat removed from exterior of tip as needed
1st layup of glass over foam rib in progress
Plastic and elastic band to keep glass from lifting due to small radius bend
