I've been working this out in my head the last few days, and spent a couple hours getting as much stuff pre-ready as I could:
These are the materials to laminate one side of the boom, from left to right is: the foam core; several lengths of 4oz. uni; the female part of the mold with packing tape, absorber cloth, and peel ply double-sticked to it; the top (side of the boom) caul with a stack of of mylar, peel ply and absorber all double-sticked to it; and the smaller strip are the cauls for the top and bottom of the boom.
I wet out the carbon uni in the long lengths, rolled up each length, then cut the several angled segments in place as the lamination proceeded. I figured this would be more tidy than trying to wet out both sides of 50 or so angled strips, all about 6" long. Next time, maybe I'd just use a single bloody piece of +/- 45 degree biax! It took almost three hours to get this all laminated and in the clamps- the very edge of this epoxy's open time.
Unclamped and freed from the cauls. Feels light, which is good...
Freed from the peel ply and absorber layers, feels lighter....
Showing 29 oz.
There's about 25% of the carbon to be trimmed away still, plus about 2" off of each end. Say 23 oz. once it's trimmed? Right on target to match (or beat?) C-Tech's 5.5# boom weight! Now, if it only turns out strong enough...
Latest filler round on the deck, backfilling against the cockpit/deck radius biax. I'll go sand it in the morning, then start laying out the deck glass. I'll do the cockpit later as its own separate glassing session, since there's still plenty of sanding, rounding over, and filling to do there.
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