I calculated the necessary dimensions of the frame and wing with FEA before beginning this process. I also attempted to calculate the necessary surface area to provide lift at the desired speed. I studied existing foils and foil designs to achieve the final result.

I MIG welded a strong steel frame. This included a base plate for each wing, a fuselage connecting the wings, and a tall mast. You can see this metal frame in the left image below. I then sandwiched the metal wing base plates between pieces of hard plywood, using a router to cut space for the metal plates. I glued these parts together around the base place, securely holding them with weights and clams as the left image shows.

The plywood I used was already cut to the rough dimensions and shape of the wing and bent using traditional wood warping methods to achieve the desired bend. The all the wood and metal securely attached I did all the final shaping using sanders and small saws to achieve the final shape. This step took forever. I needed to achieve the aerodynamic wing profile as well as maintain enough strength in the wing to support my weight.

I then wrapped it in multiple layers of carbon fiber fabric, using a wet layup method for attachment. I oriented the carbon fiber fabric so that the fibers ran along the lines of maximum tension so the carbon fiber was optimally loaded. Finally, I painted and glassed it to make for a sleek and smooth finish.

My first attempt broke almost immediately. Honestly, it was a poorly thought-out attempt. My second attempt, depicted in the right image below, worked for a few rides until the fuselage and mast both bent slightly. My third and final attempt is the pink wing shown, which still works to this day.