Contents
Contents ..........................................................................................................1
Introduction ......................................................................................................2
Overview of the production process .............................................................2
Health and Safety ............................................................................................4
Basic Design ....................................................................................................5
Equipment required..........................................................................................6
Chemicals required ......................................................................................6
Tools required ............................................................................................10
Mould manufacture ........................................................................................11
Blade half manufacture ..................................................................................13
Materials required:......................................................................................13
Preparation ................................................................................................. 14
Lay-Up Procedure ......................................................................................22
Blade joining ..................................................................................................24
Blade trimming ...........................................................................................24
Blade root ...................................................................................................25
‘Stringer’ manufacture ................................................................................25
Expanding foam .........................................................................................30
Blade finishing ............................................................................................33
Acknowledgements ........................................................................................ 34
Appendix A: Quantities of materials ...............................................................35
Appendix B: Cost ...........................................................................................36
Appendix C: Labour .......................................................................................37
Appendix D: Forces on blades and testing ....................................................38
Appendix E: Blade deflection test ..................................................................40
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