The spar caps are a critical structural item on my plane build and I wanted to learn about how to do this work before attempting it on the real thing.
My goal was to build a section of the CS spar cap and find out how thick my special UNI tapes will layup per ply and to develop a good technique.
First step was to find a piece of scap divinycell. Then I marked out a 3" trough, actually 3.1" to match my 80mm tapes. Just for the practice I put in a two ply UNI shearweb. I hardshelled it just to see how much extra time this added to the job and to try using powertools for sanding.
It adds quite a bit of time and while I think this method is good for some areas, in the end I used a wet micro layup for the real job later. I think the foam cells are so small here I'd go for the primary bond for the extra strength and skip all that sanding.
