The Corsair82: 82% F4U-1A Corsair

This section will outline the process of making the wing skins. The internal structure will be dealt with in a different section.

Making the Wing Skins - Pic 1
The new mold is cleaned and waxed in preparation for making the first wing skin. This will be the bottom skin of the left side of the center section.
Making the Wing Skins - Pic 2
This is the mold for the top skin of the left side center section. It has been marked for the placement of the PVC foam core and the wing spar cap.
Making the Wing Skins - Pic 3
A layer of fiberglass has been placed in the mold.
Making the Wing Skins - Pic 4
The core and the second layer of fiberglass are in place. The vacuum bag, bleeder ply, and bleeder material are seen attached to the left side of the mold. The vacuum seal tape is in place around the edge of the mold. All is ready to wet out the materials.
Making the Wing Skins - Pic 5
The part is wetted and under vacuum.
Making the Wing Skins - Pic 6
A close up of the vacuum attachment.
Making the Wing Skins - Pic 7
The lower skin has been removed from the mold. This skin was made using a different technique than the top skin. The process is called "Vacuum Infusion". See the section on vacuum infusion for a description of the process.
Making the Wing Skins - Pic 8
Top and bottom skins are attached to each other while being supported by the mold. Note the rear spar.
Making the Wing Skins - Pic 9
Removing the part from the mold.
Making the Wing Skins - Pic 10
Adding ribs and building up a "stick spar". This spar will be used to make a template for the real spar.
Making the Wing Skins - Pic 11
A different angle on the build up of the "stick spar".
Making the Wing Skins - Pic 12
The assembled wing skins in approximately the correct angle they will be in when mounted on the aircraft.
Making the Wing Skins - Pic 13
The landing gear doors have been marked.
Making the Wing Skins - Pic 14
Landing gear mounted in the wing. The door area ended up a mess and the gear will require a small blister on the door to cover it completely. See the landing gear section for more on mounting the gear.
Making the Wing Skins - Pic 15
A wire mesh has been placed over the gear. The gear was first covered in plastic to protect it from resin.
Making the Wing Skins - Pic 16
A stiff layer of fiberglass (supported by thin wood strips) is used to cover the wire mesh.
Making the Wing Skins - Pic 17
You can see that the wing contour has not been changed much to accommodate the landing gear.
Making the Wing Skins - Pic 18
Body filler has been added to fair in the new area and clean up the rest of the surface.
Making the Wing Skins - Pic 19
The wing has been repainted. Again, notice how little the wing had to be changed. You can see the small bump needed to give the gear clearance. This wing will now be placed back into the mold for the top skin. It will act as a plug to build a new mold for the bottom skin.


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