Aerodynamic article with partial outer portion and method for making

Abstract

An article having a design external aerodynamic shape includes a body with a body external surface and an outer portion external surface of an outer portion bonded with a part of but less than substantially all of the body surface. The external surfaces of the body and outer portion each define less than the design external aerodynamic shape. However, together they define such shape. The article is made by selecting the design external aerodynamic shape from an existing article having a first body and a first outer portion. A replacement outer portion is selected in an amount less than the first outer portion and bonded with a region less than substantially all of a replacement body external surface. The replacement body has a replacement body external surface and replacement body external shape different from the first body substantially by that amount. The replacement body is made with the replacement body external shape. Then the replacement outer portion is bonded with the region of the replacement body external surface. The result is that the external surfaces of the replacement body and replacement outer portion together define the design external aerodynamic shape.

Dependencies are inferred from the claim text.