Plans have you cut out the baffles as raw foam and then glass them when they are in the stakes. I'm glassing mine now and will tape them in place in the strakes instead. A much better method.
I did this over about 10 days. I got all my foam collected and I seem to almost have enough of the 10mm thich divinycell to do the strakes. However not quite enough.... I do have some half inch foam so as you see in pic 1 I have routed it to the right thickness. After a clean up sand it was fine.The little map is the result of some hours working out how to cut the pieces I have in the most economical way.
Pic 2 is one of the layups. 10mm H35 Divinycell, 1 ply of BID each side and peel ply. I tried it with plastic on top as well but this is not good on bigger pieces. The EZ epoxy is quite different to the Araldite 360 I have used for the rest of the plane. Much thicker and wets out differently. I did get a few bubbles appear that must have risen some hours into the cure. Easily fixed later.
Pic 3 has all the baffle material for both sides (less one piece I did later). I'm still to finalise the exact baffle sizes. However given these pieces needed two cures and I didn't have enough bench space to do them all at once its another step completed.
