I worked in George Applebay’s sailplane shop during high school and college. There I learned machining, welding, drafting, and composite fabrication. I also met Jon Sharp who was our shop foreman. I crewed for Jon at his first air race in Mexicali, Mexico in 1978 and I continue to crew for him today. I earned a degree in Mechanical Engineering in 1981.
Formula One Racing Propellers
I have been building composite racing props since 1988.
The first ones had carbon fiber skins with a unidirectional fiberglass interior. Jon Sharp flew my first prop at Reno on his Cassutt Aero Magic in 1988. In 1991, I switched to all carbon fiber construction for Jon Sharp’s Nemesis race plane using unidirectional tapes in place of fiberglass. In 1993 I standardized on a unidirectional carbon fiber roving interior and developed a semi-automatic filament winding process. This process yields repeatable results with good out-of-the-mold static balance.
I made my first all-composite aerobatic propeller in 1994 using a carbon fiber roving interior and the semi-automated winding process.