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Bryan:

The glass used on the 235 wing skins (and probably the other models as well)
is re-impregnated at the manufacturer with the optimum amount of resin and
then frozen to stall the cure of the epoxy. Once layed into the molds, in
the proper sequence, e.g., fiber glass - foam - fiber glass, a airtight
plastic sheet is layed over the assembly and a vacuum is drawn to suck the
plastic down tight against the sandwich and force the layers into the female
form. This sheet of plastic also provides uniform pressure over the entire
inner layer to insure the required tight contact between the layers so that
all surfaces will bond. Beneath the plastic, numerous batts of a fibrous
material is distributed about the inner skins to provide an air path to the
suction point, insuring that the plastic bag is tight against all parts of
the skin surface (no bubbles). After this is done, the entire assembly is
placed in an autoclave and cured at an elevated temperature. The result is a
perfectly molded part with closely controlled properties.

It is highly unlikely that you could produce acceptable Lancair wing skins
with anything approaching the required strength, using anything less than
the original methodology. In my opinion, trying to make such components
using a wet lay-up is totally unacceptable, regardless of how accurate your
molds might be.

Just one person's opinion.

Dan Schaefer

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LML website:   http://www.olsusa.com/Users/Mkaye/maillist.html
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Please send your photos and drawings to marvkaye@olsusa.com.
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