We build our wings and elevator around a foam core, covered with wood and then glass, before spray painting them. The wing spars are in carbon, and we install a carbon d-box. We’ve built a large number of gliders this way already, it ensures they’re very robust and light (we expect the 5.14m JS3 to be around 6kgs).

Foam cores means cutting the foam first. Again, we do this the old way, by hand…. Quite a bit of work to do 4 gliders with exchangeable outer wings, and a nice pile of foam as a result. Unfortunately I didn’t get a photo of all the foam as we distributed it among the team to avoid the pileup in the workshop….