Beam exterior

Laminating the exterior of the beams turned out to be a logistical challenge. The many overlapping carbon patches, all in slightly different sizes, had to be positioned accurately and in the correct sequence. The top and sides of the beam were relatively straightforward, but the underside was a different matter altogether.

I chose to keep the lower folding strut molds in place for as long as possible. While this helped maintain alignment, it also created an awkward obstruction during the lamination process. In addition, the beambolt recess and the upper folding strut recess required extra time and care to execute properly.

Throughout this phase I was slightly concerned about releasing the lower folding strut molds. They were made from three layers of plywood, with packaging tape applied as the release surface. To minimise any risk of the molds sticking, I sprayed the taped surfaces with an additional coating of McLube Sailkote.

These concerns proved to be unnecessary. By installing two tapped threads and using a few wooden blocks as reaction points, I was able to extract the molds smoothly and without difficulty.