I got the horizontal spar started today. The two sides were sanded on the edges to be the correct size and be symmetrical. The face of each side on the joining edges was scuffed with 60 grit and 1/4″ of foam was dug out from the ends.
I made a 20gram mix of 5 min epoxy and thickened it with flox to be like thick cream cheese. I then packed the ends of each half where I had dug out the foam leaving a lot sticking out.
I made center marks at 3 places on each half and put plastic wrap over the location of the joint. I put the two halves together and lined up all the dots along the laser. I scraped off any excess flox.
The two halves aligned. Noted the pencil alignment marks.
I sanded off any excess 5min flox and took off the shine with 60 grit and trimmed the edges with a utility knife.
Last thing I managed to cut 2 layers of BID for both sides of he joint. I cut the top piece to size and then added 1/2″ on both sides to add a slight taper in thickness to avoid stress risers.