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A Two-Day Intensive Workshop. This class has been held since 1983.

Intended for all who are building a composite aircraft such as the Stallion, Lancair, Glasair, Wheeler Express and for those building a prototype of their own design. You will learn how to fabricate and assemble parts and build a complete aircraft using composites and composite material fabrication methods. Learn the secrets of the trade in building cored structures using foam and honeycomb. This project will include learning what resins to use were and how to mix and apply them, shaping foam, wet layup procedures, flanging, bonding metal to composites and composites to composites using resins and adhesives, pop riveting, and much more. The project will be built using a simple moldless construction method used in building prototypes. Learn where to buy what and for what price. The following specific topics will be discussed during the class.

RESINS: How to layup parts using vinylester, Derakane 411-400 and epoxy, Epon 862/TETA, resin. Mixing ratios, Sticky Stuff Dispenser, methods for mixing by weight and volume, applying, and storing, and safety precautions. How to make and apply micro and flox. When and when not to post cure to increase strength and shorten cure cycle. Mold making and gel coats and release agents. Film and past adhesives used in the industry and how to prepare aluminum and composites to properly use them.
REINFORCING MATERIALS: Were and how to use bidirectional fabrics and unidirectional taps made out of fiberglass, Kevlar, and graphite (carbon). How to layup parts using these reinforcing materials by wet layup. Cutting on a bias. Special tools needed for cutting and drilling.
CORE MATERIALS: Foam and honeycomb core materials and how and were to use them. Film adhesives for bonding honeycomb cores to face sheets. Phenolic and metal inserts in cored structures and how to reinforce composite structures for mechanical attachments.
PREPREGS: What materials are available and how to use them. life and storage requirements and cure cycles. Vacuum bagging.
WET LAYUP: How to wet layup epoxy and vinylester resin parts over a core and in female molds.
VACUUM BAGGING: How to building a vacuum bag system which includes a simple low cost vacuum pump. Bagging films, peel ply, bleeder material, hosing, and fittings. How to build an oven for curing prepreg materials. A simple temperature controller. How to build molds using high temperature resins, plugs, and finally parts.
MOLDLESS METHOD: Hot wire cutting styrofoam core and making wood formers and using urethane foam sheets for the fabrication of a prototype aircraft.
AIRCRAFT ASSEMBLY AND FINISHING: How to join and repair composite material parts. Finishing, sanding, and paints, primers, and fillers for wet layup and prepreg parts.

Class will be held at Aircraft Designs, Inc. 5 Harris Ct. Building S. Monterey, CA 93940. Advanced registration is required and no refunds unless mutually agreed upon!  Registration fee: $595.00 includes all composite materials for project, workbook, and lunches. For more info contact Aircraft Designs, Inc. Telephone 831-621-8760.