The design of the new rotors for Goliath is complete. There's also been a lot of effort spent making a separate repository for the rotors. The goal is to provide everything a person would need to manufacture their own rotors from scratch using the process used for Goliath. Manufacturing of the rotors has started, but there has been some issues machining the new rotor cores.

To avoid any confusion, the numbering system for the cores started with original cores built for Goliath (Cores 1 through 4). Two were destroyed in the second test and were replaced with rotors 5 and 6.

For the 7th core, in addition to use the new tool paths, there was an attempt to optimize the cutting path and reduce the cut time. The optimization worked for one side, but ruined the leading edge on the other. It was decided at that point to hold off the optimization until after enough cores were completed.

The 8th core came out acceptable with no issues. The 9th core had a bad trailing edge. It appears that the bottom cuts were performed with the z-axis slightly too low and too much material was cut off the rotor and the trailing edge broke. To help ensure the Z-axis was aligned properly for the following propellers the spoil board was re-machined to ensure it was level.

The next core, the 10th was completed without issue and was likely the cleanest of the cores that have been made. The 11th core, was the first of the new clockwise cores since cores 8 and 10 were counter-clockwise rotors. The tool path was loaded and the router was left to rough out the top of the rotor. This was the result after returning the the router:

Making additional rotors is on hold all the birch plywood is used up. Meanwhile the new tool paths will be tested out on a purely foam blanks to avoid wasting more birch. Work can also start on fiberglassing cores 8 and 10. There's still a lot of work left to do, so it'll be several weeks until all of the new rotors are completed.