Procedure:
Tube Preparation
Sanded inside of tube
Tube layup: 3 layers of carbon fiber (cut piece slightly longer than necessary for some wiggle room)
-Used Systems 3000 epoxy but didn't oven cure after layup
Root Bond and Root Fillet
Did root bond
AFTER root bond, attached phenolic LE to G10 fin core (did after root bond because phenolic wouldn't have fit in the fin can jig)
Root fillet (West Systems fast hardener + colloidal silica)
Carbon Fiber Cut-outs for Tip-to-tip Layup
Quentin designed CF cutouts (6 sizes --> small to large)
Lasercut CF cutout
Preparation of Vacuum Bagging Materials
Prepared vacuum bagging materials
Tip-to-tip Layup
Mark centerlines on tube and CF cutouts
CF didn't meet up in certain places (ends of tubes, some were barely large enough to cover the fins)
Only had one ply going all the way to the end - saw exposed G10
Triangle of exposed area near the fins --> adjust size of cutouts
Vacuum Bagging
Vacuum bag was 32 x 38" (this is TOO BIG, make smaller next time. For the test fin can though the bagging was too SMALL, so find a good middle ground)
Oven Cure (ATTACH SOP)
Positioned fin can horizontally as shown, because there wasn't enough vertical space in the oven we used. This may have caused the fins to splay (weight of the tube + epoxy loosening --> fins move), so in the future we should position it vertically.
Post-processing
Vacuum bagging materials were difficult to remove, but not impossible
Used Dremel to get rid of CF on trailing edge and either end of tube (in future, taper trailing edge of G10 to get smoother layup quality)
Sanded CF on leading edge
