Abstract: A method of manufacturing a lightweight composite propulsor blade of spar and shell construction comprises forming a composite spar (30) having an elongated foam body (20) bonded to a short metal retention tulip (10) and overlayed with a dry braided wrap of angular structural fibers and substantially unidirectional spanwisely aligned structural fiber plies disposed between the braided layers; adding a leading edge foam body (42) and a trailing edge foam body (44) to the spar assembly to form a blade subassembly (50); providing a dry braided fabric wrap over the blade assembly; disposing the fabric covered blade subassembly into a shell molding die and simultaneously impregnating the dry spar fabric wrap and the dry shell fabric wrap with a curable resin material; and curing the impregnated blade subassembly.

Abstract: Press element insertion apparatus (86) is a press-like apparatus used to insert pins (82) or sockets (82) into a cable connector (84). Clamp (104) is adapted to securely hold a pin (82) or socket (82) with a conductor attached for insertion into a cable connector (84). Clamp (104) readily releases the pin (82) or socket (82) after insertion into a cable connector (84) by operating lever operated cam (120) which releases movable jaw member (118). Internal springs (122) cause movable jaw member (118) to laterally release pin (82) or socket (82). The cable connector support (90,92) is a two-axis position guide that prevents cable connector (84) from rotating during cable fabrication while simultaneously providing two degrees of freedom that are necessary to insert pins (82) and sockets (82) in an array (86) of element insertion locations.