Birth of the Blue Missile

MUUMUU,
The reason the “PLUG” is made out of wood is so that, just as it was needed in this case, is so that it can easily be modified. The wood is covered with fiberglass and gloss coats of epoxy so it can be polished out facilitating the piece’s release from the “mold”. Until I’m happy with the shape of the piece, I’m just making one for me. Once the shape is good, next comes the ply schedule. Right now it’s the thickness of a paperclip. Way too thin. But that enabled me to put it on the car and take more measurements to tweak the shape. Until I’m happy with the part I’m not making a negative mold for the finished piece. Even in that case Ill probably use wood for a lot of it. It’s easy to shape and takes the compressive forces of vacuum bagging, also I’ve been “patternmaking” for decades, so its easy for me.
As far as “Kevlar” and most other aramids go, unless you are looking for ballistic protection they are a waste of space. See if you can find a micrograph of Kevlar in matrix. What most people do not know is that aramids never really bond to the matrix. Which is why aramid composites that get submerged in water, suck water into the matrix via capillarity and get heavier.
I got involved with composites in 1980, and have gotten to know a lot of the people that have developed the industry. If composites interest you that much you need to go to the “IBEX” convention in Ft Laud.
Back to work
Andrew