REFLECTOR: Winglet trimming

[Andrew Ellzey]

Steve,

You should call the factory to let them know that there is a problem with 
their winglet template and get an conformation to what I did for mine. I am 
also building my wings and winglets. I had the same issue as you are talking 
about. Put your winglet back in the billet half that matches the inboard 
side of the winglet. Mark the lines on the billet half, the 28" mark will 
fall on the billet half and the 12" will fall on your winglet. Now mark the 
1" foam trim line on your winglet per the manual. This line will fall 
entirely on your winglet. Sand your billet half to match the contour of the 
trailing edge where the line comes off the foam of the winglet. Line you 
billet half with plastic to make a mold half for your lay-up. Do your 
inboard lay-up per the manual leaving enough cloth for the entire size per 
the manual. When you put your winglet in your billet half it will form your 
trailing edge for the correct 28". After it cures you will trim the foam 
back the 1" on your winglet per manual, and this line will fall on the foam. 
The manual also doesn't tell you what to do with the top of the winglet, 
leave it squared off like it came out of the billet or round it off. I 
rounded mine off to a nice aerodynamic shape. There are now three of us on 
the Reflector that has found the same issue, there probably will be more.

Andy Ellzey


----- Original Message ----- 
From: "Steve Goldman" <steve at fatcatair.com>
To: <reflector at tvbf.org>
Sent: Saturday, October 07, 2006 6:58 PM
Subject: REFLECTOR: Winglet trimming



> Well this might be a factory question for monday but we'll see.
>
> I got the winglets out of their billets today in hopes of starting on 
> them.
> I got stymied almost immediately. The manual calls for marking a spot 28" 
> from
> the leading edge at the bottom and 12" at the top and trim to the line 
> connecting
> those marks. Well I have more than 12" of foam at the top but I only have 
> 27.5"
> at the bottom. So I'm not sure what to do. The manual does say the 
> important
> thing is for them to be as identical as you can do them and since both are 
> 27.5"
> I could make them match up.
>
> I took out the wing trimming template to see what the winglet foam looked 
> like
> next to it and they look short there too. (The curve on the inboard side 
> looks
> remarkably different too but the geometry when it lays on the wing could 
> be
> part of it.)
>
> -- 
> Steve Goldman
> '77 Tiger N28531
> Velocity XL5-RG (T-3465hrs 1%)
> Pittsboro, NC (9NC8)
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