Today the focus is fabrication of the fillets that cover the open area behind the prop blades. These fillets must be shaped to fill the space and preferably will be flush with the surface of the spinner. To be flush the fillet needs to be about .063" thick. Since I couldn't find any .063 scrap in the shop I decided to laminate two pieces of aluminum (.040 and .025) to get very close to the desired .063.
I began by making the inner lamination from .025 and then using it to pattern the outer layer of .040. The outer layer needs to be slightly larger in length because of the larger radius. Also, it is necessary to rivet the two layers together after they are shaped in the slight arc to fit the backplate. Actually, once the shaped layers are riveted together the fillet holds the permanent arc that matches the radius of the backplate. Before riveting I bonded the two layers with a very thin coating of quick drying epoxy as well. The fillets turned out really nice.
