At first I did the Hysol over bare foam. When the horizontal tip got hit with a light tap of hangar rash it shattered a golf ball size area and required surgery. Reasoning the horizontal tip will probably see more unintentional contact in the future I went for a little more protection.

The new tips consist of balsa wood covered with two layers of 4 oz. Fiberglas cloth saturated with West System epoxy. A little body filler and some sanding completed the job. The tip can now withstand a much harder blow if someone says "oops!... Sorry"

The West System epoxy can withstand more heat than any fabric and will not soften when covering the tips.

John P