James and I measured up the wing tips, then folded an ally sheet as a mold for the fuel tank walls. One end opens out slightly, while the other tucks in near the lights. We'll install a wall doubler to ensure fuel can't leak into the light space easily. We wet out two layers of 400gsm woven fibreglass mat with fuel compatable vinyl ester resin.
Tomorrow we'll line the inside of the wingtips with glass and vinyl ester resin (forming a mechanical bond to the epoxy resin wingtips), plus reinforce the edges with carbon fibre to help support the extra weight.
We'll set the walls in place only after the light mounts are enlarged and when the tips can be fitted into the wings to ensure exact sizing.
