On this work trip, I took my styrofoam tip blank and cut it out to a basic shape with a hacksaw blade. Out in the yard away from the shop Ray set up the portable verticle belt sander on the make shift saw horse table top so I could do my final shaping.

I made a line around the entire foam block as a sand to line. this was based off of the outline of the right wing tip. I then started to sand away the material a little at a time keeping my shape as close to the shape of the tips that Ray had ordered from Dave Thatcher a while back. It took a bit of time to get it to the desired shape, but once in the ball park and we were both happy with the way it looked, a finish or detail sand was in order. I used a piece of 120 grit sand paper and smoothed out the edges and dressed up the profile till it was just about identical to Rays completed ones.

The tip of the wing was taped up to keep any resins from getting on it at the time of the glass lay up. The foam tip was then taped to the end of the wing with clear plastic tape. Several layers were placed on both sides of the tip making sure that all areas of the foam were covered. The tip was then painted with a release agent that I had purchased from West Marine the other day. This release agent will hopefully work and not stick to the tip.