As an unexpected treat for my visit I was able to assist in making my blades. They only make the blades when the weather is perfect. Because there is only one mold they can make 1 blade per day.This assumes that all of the preliminary work is done beforehand. This includes:
1. Cut the carbon fiber and fiberglass to predetermined shapes. There are I think 8 layers per blade plus the gel coat. Each one is a different length and bias orientation. They cut a bunch at a time from patterns and store them until needed.
2. Glue brass rod to spar
3. Apply the gel coat to the mold and let it harden
4. Have all of the resins premeasured. In Photo 1 I show Bobby stirring some resin. Before the layup process starts they have several of the white buckets filled with a premeasured amount of resin, the type and amount is marked on each bucket. The applicable hardener is sitting beside it. Bobby and the other guy, whose name escapes me, go through a checklist before any resin is mixed. Much like breifing for an instrument approach. After the briefing they start the layup.
All of this is done before starting the layup.
The blades are mostly carbon fiber with some fiberglass at the root for bulk. After the layers are in and all of the air bubbles are worked out, the spar in set in place. The spar is an aluminum extrusion of primarily rectangular cross section. There is a groove in the "leading edge" of the spar that hold a 3/8" brass rod that run the full length. The brass rod is glued in place well before the layup starts. This is where the weight of the blade comes from.
After both halves of the blade are done they are glued and clamped together overnight. The next morning they are removed from the molds set on a rack and the process is repeated for the second blade.
Bobbly says that now with their new manufacturing techniques that the blades are so close in weight that static balancing is typically not necessary. We will see about that.
