4. When dry, these blade halves are then carefully cut and the edges
tapered to that the two halves fit carefully together.
5. A wooden insert is fitted into the root of the blade. This provides
material for which to screw into and provides some compressive
strength.
6. A fibre-glass ‘stringer’ is fixed into one blade half. This is carefully cut
down so that the other blade half fits exactly on top. This ‘stringer’ gives
strength to the blade from root to tip.
7. Additional pieces of fibre glass mat are stuck to the ‘stringer’ using
resin. This gives a large area onto which the other blade half can be
stuck.
8. The other blade half is stuck onto the first. This is then fitted back into
the mould and clamped together to ensure it dries in the correct shape.
9. A two-part expanding foam is then used to fill the blades.
10. Any imperfections in the blade are then filled with good quality filler
which is then sanded back. A thin veil is added to the leading edge to
join the two halves and for protection (this edge will be worn away in
time due to the wind). The blade is then sanded to a smooth finish.
11. Depending upon the surface quality and desired finish, the blades may
need to be painted.
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