I'm working on my biggest wing yet. This is going to be about 1240cm^2.

 Molds made from expanded PVC and filled with JB Weld epoxy and glazing putty.
Designed on my computer and cut with a CNC machine.

 Foam core. Also cut with CNC. Aluminum plate so the screws don;t pull through the holes when its screwed to the fuselage.

 Cutting ribs for the frame.

The mold will be clamped to this frame to give it a uniform dihedral.

I still need to apply the release agent to the mold, but I may be ready to lay up the epoxy and carbon today. I will probably have the new wing ready by next weekend, if not sooner.

Great day on Pymatuning Reservoir, though the wind was light and up and down, and then shut off. I managed to get some really good, stable flights with the windfoil. I managed to fix the issue of the mast shifting forward in the Tuttle box by adding a carbon plate.

My arms are still getting real tired quick despite being fully harnessed in. I feel the need to constantly push the sail forwards. But I still managed a couple flights that were something like halfway across the lake. I feel I could keep flying indefinitely or till my arms got too tired as long as the wind kept steady.

Thanks to Thomas Sarell for the video.