Aero Poxy Light Filler

General Composites Discussions Composites Talk
#1

I just ordered some of this stuff, but I want to make sure my thoughts are correct on its use…

http://www.aircraftspruce.com/catalog/cmpages/aeropoxylight.php

I’m going to lay in some Nomex honeycomb on a cured piece of carbon (bottom of a ski board), and I’d like to fill in some gaps around the edges and fill in some of the bottom curves of the ski. I’m thinking that having a flatter surface to bond the Nomex honeycomb, the better…the AeroPoxy Filler will allow me to smooth the bottom out and fill in around the edges.

Now, I would like to do this DURING the layup. Is it smart to use the filler on the bottom, spread some resin around, then lay in the honeycomb? Then fill in some gaps around the sides of the honeycomb with the filler, then lay over and wetout the next 5 plys of Uni-carbon? Then bag and cure the AeroPoxy Filler, honeycomb, and carbon all together?

Thanks.

Also, I’ll add a picture so you can get an understanding of what I mean about filling in around the edges of the honeycomb. Also, the bottom of the board shell is curved…and I want to use the filler to help smooth it out. This picture is of the bottom shell of the board and the honeycomb just laying in there – I have not cleaned up the flange yet, because it’s all going back in the mold…

#2

Not that I’ve done this but having the filler there to fill the gaps can only help. It’s lightweight and you’re not going to be penalized too much in term of additonal weight, yet you’re taking care of spots where delamination can occur. So I think it’s a good idea. It’s worth trying at least.

#3

Generally, it is not necessary to use a filler as an interface between a cured skin and honeycomb- unless the skin has massive undercuts (unlikely, since the carbon would not conform unless it was a multi-part layup). If the issue is just fabric print through, the nomex will deform under vacuum to make a good contact (keep in mind, you have a huge pressure applied to what amounts to a very small surface area (web of the nomex is less than 5% of the overall area of the sheet)). All you need to do is wet the face of the nomex with epoxy- and it will form fillets with the cured skin via capillary action. Or, use a thin layer of carbon/resin as a surrogate for an adhesive film. Or, if you can bake the mould, use a conventional adhesive film designed for this purpose.

Frankly, you will have so much resin pouring through the honeycomb from the top skin (assuming a wet layup in a vacuum bag) that you will not really need much else :wink: Just make sure the nomex is clean and oil free.