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All airfoils and endplates are separate parts that will be screwed together.
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Front Plate Dimensions:
23”x12”x0.25”
20”x8”x0.25”
4.75”x6”x0.25”
Front Airfoil Dimensions:
15”x12.5”x2.5”
15”x8.5”x1.5”
8.4”x6.25”x1”
Rear Plate Dimensions: 24”x31”0.25”
Rear Airfoil Dimensions:
14”x3.5”x40”
8.5”x1.5”x40”
6.25”x1.25”x40”
Materials
Fabric
2x2 twill 3k carbon fiber fabric
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The nosecone consists of two primary panels and a top panel. The sidepod is one piece.
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Nosecone primary panels: 36”x22”x5”
Nosecone top panel: 50”x28”x22”
Sidepods: 36”x12.5”x11.15”
Materials
Fabric
2x2 twill 3k carbon fiber fabric
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The seat consists of a single carbon fiber body, the seat shell.
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Seat (approximate) dimensions: 9”x18”x12”
Materials
Fabric
2x2 twill 3k carbon fiber fabric
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Orange Tooling Gel Coat https://www.fibreglast.com/product/Orange_Tooling_Gel_Coat_just_gel_coats_188
Vacuum pump, tubing, fittings
Vacuum bags and tape
Paint rollers
Mylar film
Vacuum bagging breather/bleeder https://www.fibreglast.com/product/Breather_and_Bleeder_579/Vacuum_Bagging_Films_Peel_Ply_Tapes
Dremel
Electric sander/sandpaper
N95 respirators
Gloves
High-Level Procedure
Taking place early December 2023 or January 2024
Mold [2hr active]
The mold will be covered in gelcoat. The setup and fabrication time should take ~1 hour, and the gel coat will cure in ~45 minutes. Mold will be fabricated and stored in a ventilated area during curing and removed once curing completes.
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The seat shell will be laid in one work session. From setup to bagging/cleanup, the process should take ~2 hours. After the seat shell is bagged, it must remain in the ventilated area with the vacuum pump on for 1 hour. After this, the sealed bag can be brought back to the NER bay and left for 2-7 days until fully cured.
Finishing [~3 hr active]
After removal from the mold, the seat shell will need to be finished. This will involve cutting off the ends with a dremel and smoothing the surface and edges by sanding. This should take a few hours and be done in a well-ventilated area with proper PPE, including N95 respirators, gloves, and coveralls.