Outboard cores

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I didn't pay much attention to where the joints were when I cut my planforms. I should have. You see, when I layed my long foam blocks on the table, the long edges didn't always sit flush with each other. So I made long vertical cuts so they would square up to each other. Well, my blocks were rather wide (which was kinda nice) so I had alot to work with and that is how my mate lines got a little off. I didn't think it would matter much. It does though. It is actually possible to micro all the cores back together and if your mate lines are not at least close to where they are supposed to be, then when you need to hotwire conduit holes, your saw would not pass through cured micro. At that point, you would get that sinking feeling in your stomach, you might say a bad word or two, maybe even take a hammer to a core or two. I got lucky though. I'm not sure if the above core is supposed to end up like this, but the pie pieces are easily and accurately glued back in place using a template on one side and by feel on the other. You can also see the little bit of leading edge sitting there. That piece comes from the scrap foam you WILL need to add to the leading edge.

On someone else's recommendation, I kept the flash on the leading edge to help sight things in later on. Turns out, my cores do have a slight bow in them. Well, not all of them.

Using the template to align a piece back in place during micro cure.

This notch is cutout so the hotwire saw can gain access to this template.

Since my borrowed hotwire saw won't fit into the notched area in the above photo, I threw together this mini cutter in about twenty minutes.

Email -- Jay Hegemann