The cooked foam episode

It's cold here in the garage. Resin likes about a week to cure in the cold and we don't have a week for each layer. Between us we have three 500w work lights so we fired them up and kept them around near the foam. We carefully monitored them to make sure they weren't too hot for the foam and got away with it for a day or so.

Next time you're building a DDWFTTW vehicle propeller in your cold garage and using quartz work lights, here's a little tip -- turns out that the last 5 minutes of the bulbs life, right before it burns out, it produces MUCH more heat than normal. We had a light that had been in the same place for hours and hours with not a problem (all the way back to the day before) and all a sudden we noticed that there was a blister on the foam and then 'poof' the bulb went dark.

After this episode, we went to Lowes and bought a propane salamander heater to bring the garage up to temp without risking the foam. We were able to sand out the blister and fill the void, but it could have been a lot worse.