Above: I cut away the damaged skin but
retained as much of the healthy skin as
possible. I made some thin aluminum angles
and floxed to the spar to attach other
aluminum forms to.

Here I have bent some thin aluminun to
conform generally to the leading edge. This is
not structal but only to have something to
hold the foam. Actually it is very strong.
Below the spar is 1/4 inch Last-A-Foam
glassed on both sides and floxed in place.

Some things don't work. I tried to use Great
Stuff spray foam I sanded it down but it was
too soft and too porus to be used so it was
removed.

This time I placed plastic over the area to be
repaired, traced around it with a sharpie then
removed the plastic and put it on a sheet of
styrofoam and cut along the line and had a
piece of styrofoam to fit into the repair area.

The duct tape is holding a piece of the original
skin that has been floxed back into place. see
upper right picture.

Here the styrofoam has been glued into place with
two-part foam and is being weighted down until the
foam dries

Blue styrofoam will be cut to fit into voids such
as this then small cracks between the skin and
styrofoam will be filled with two-part foam. I
have learned to use two-part foam very sparingly

The leading edge, tip and trailing edge
has been glassed with two layers of
fiberglass and now has pel-ply over it.