We have started making test rib sections, using various different glues and processes to join the wing rib skin to the foam rib section. Once we've sliced off the 6mm wide rib sections, weighed everything and done some pull tests, we'll decide which glue and which manufacturing technique to use for the production ribs.
So far, polyurethane glue is looking promising (and lightest), and vacuum bagging is a lot easier and gives a better result than clamping with clamps, or clamping with tape.
We'll also be trying different kinds of foam. The first 4 test rib sections used Foamular 150 pink foam, which is available in a maximum 2" wide material. We'll also try Foamular 250, which is about 7% denser (and thus heavier for same rib size), but is available in 4" wide material, and "one pound" EPS (Expanded Polystyrene) foam that is about 60% of the weight of Foamular 150.
Below are some photos of the process of building the ribs, from cutting out the rib skins (aka 'caps'), forming the jog in the skins with a custom clamp, gluing the strips and then clamping or vacuum bagging them.
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| Clamping with Clamps |
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| wetting the surface to activate the polyurethane glue |
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| Adding peel-ply |
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| Clamping with tape |
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| Fully 'clamped' |
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| Taped for vacuum bagging (a lot less tape!) |
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Attaching Vacuum
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Peel Ply & Bleeder material
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