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[BUILD LOG] Project Ametros: Scratch Built Carbon Fiber Case + WC - Mar 11, 2012 - Page 10

post #91 of 200
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6.0 Mold Making + Carbon Layups!

It was a super busy weekend for me. I couldnt care less about the super bowl this year so I decided to spend the entire weekend in the shop working on Ametros making molds and doing layups. I decided to start making the mold for the lower pedestal first.

Making the Molds

6827380073_349c66ab53_b.jpg
The weekend started off like this; cutting up sheets of 3/4" MDF to begin making the first molds.

6827380171_de52e3cc2b_b.jpg
All of the MDF was screwed and glued together.

6827380199_fcbc08f8dc_b.jpg
Titebond III is some amazing wood glue.

6827380259_0f12b8b5d2_b.jpg
Quick mockup.

6827380301_870bb7fb97_b.jpg
This is where things got really messy. I wanted to make sure all the sides were even and square, so I machined them down on the mill. Cleaning up the mill after all the machining was a pain. Its not like machining metal or plastic where you can just blow off the chips, the machine has to be vacuumed, wiped down, and reoiled after machining wood.

6827380339_3bee131c46_b.jpg
1" Ball mill for the radius

6827380367_be6b81e84d_b.jpg
I used putty to smooth out any milling marks or dips in the MDF.

6827380421_8baa925089_b.jpg
All sanded down ready for paint!

6827380467_fc62a5a768_b.jpg
Primed!

6827380487_0b2352b2cf_b.jpg
These infrared heat lamps/paint dryers are the best investment our shop made. Dries paint/primer in 15 minutes and I used it to cure carbon fiber later in this post.

6827380513_29cc046c1e_b.jpg
You can see the bottom got the same sealer primer treatment as well. I also marked out the outline of where each piece needed to go. The sides were screwed down so they can be removed later to remove the carbon shell.

6827380579_cbfa415842_b.jpg
Pedestal mold completely assembled.

6827380641_f64407ed8b_b.jpg
This is me, making a mess working on a mold for some of the case's internal structure.

6827380671_bf52612d85_b.jpg
More of the same mold for the case's internal structure with a corner radius.

6827380713_0ff07560bf_b.jpg
Here's another mold for another piece of the internal structure. I had to machined down 1/4" of material to get a 1/4" radius seen here.

Time to Lay Up Some Carbon!

6827380771_5829695016_b.jpg

6827380805_794e156588_b.jpg
After spraying a LOT of mold release (I really dont want this piece sticking with all the carbon needed and time spent on the mold.) I brushed on some resin to help hold the carbon in place before wetting out.

6827380881_f94be61fa3_b.jpg
Finished the first layup.

6827380943_c2ddcaa16c_b.jpg
Laid up and trimmed curing over the next few days before I pull the mold.

I'm excited to pull the pieces out of the molds later this week once they have cured for a few days. Until then, I'll be working on the reservoir! Thanks for looking!
Edited by motorsportcfd - 2/6/12 at 9:23am
Ametros X1
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post #92 of 200

Very nice. What are you doing about the corners? You doing anything for seems?

post #93 of 200
Quote:
Originally Posted by animal0307 View Post

Very nice. What are you doing about the corners? You doing anything for seems?

This.
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post #94 of 200
Quote:
Originally Posted by motorsportcfd View Post

It is just glued together with the same resin I used to layup the carbon fiber. I just machined the molds for the carbon fiber gussets today. Gussets will go in each of the corners to give it some more stability as it is not very rigid right now.
post #95 of 200
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Quote:
Originally Posted by animal0307 View Post

Very nice. What are you doing about the corners? You doing anything for seems?

When I do my layups, I try my best to avoid the seams. One method is to overlay the each layer and align the weave. In the above mold, I use two pieces to do the sides since the perimeter is ~75" and my carbon is only 60" wide. The first layer was laid along 3 of the sides so there are no visible seams in two corners. Then the other layer was then laid and adjusted until the weave was aligned. I just hope it stayed that way.

For the tower chassis, I am making gussets for each of the corners to help strengthen it.

Hopefully that answers your questions? thumb.gif
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post #96 of 200
I love carbon fiber, and I love scratch built cases.... jesus man if you're trying to impress me there are easier ways wink.gif

The build is out of this world. Keep up the good work, the good photography, and the frequent updates.
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post #97 of 200
Quote:
Originally Posted by motorsportcfd View Post


When I do my layups, I try my best to avoid the seams. One method is to overlay the each layer and align the weave. In the above mold, I use two pieces to do the sides since the perimeter is ~75" and my carbon is only 60" wide. The first layer was laid along 3 of the sides so there are no visible seams in two corners. Then the other layer was then laid and adjusted until the weave was aligned. I just hope it stayed that way.
For the tower chassis, I am making gussets for each of the corners to help strengthen it.
Hopefully that answers your questions? thumb.gif


I'm content. I was just wondering why you where using a "interior mold" as opposed molding it around the outside so you could see the weave instead of hoping for the best.

post #98 of 200
Thread Starter 
Quote:
Originally Posted by animal0307 View Post

I'm content. I was just wondering why you where using a "interior mold" as opposed molding it around the outside so you could see the weave instead of hoping for the best.

Ah! I'll explain a little more. By using the negative (female/interior mold) you get a higher quality surface finish since the mold is polished to a shine. The resin smooths out along the mold leaving a nice finish much like the interior chassis panels.

Unfortunately, the two parts that I made this weekend are now junk. I rushed things and the primer stuck to the carbon fiber. doh.gif First time in 9 years that's ever happened to me, but it was a lesson to not be impatient. I'll make a new mold later this weekend.
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post #99 of 200
Normally I'm not a big fan of carbon fiber in builds, but this stuff looks pretty dang legit. It's awesome you get to cut it out on a flow jet too. biggrin.gif Nice job so far thumb.gif
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post #100 of 200
Thread Starter 
7.0 Machining the Reservoir Parts!

One of the biggest features and focal points of this build is the waterfall reservoir with dualing "fusion tubes" in the front of the case. The reservoir is pretty large, measuring almost 20" tall and 4" wide. The "fusion tubes" will be made out of 3/4" fluorescent blue rod, lit up by super-bright blue LED's at the bottom. The effect is a glow that one would imagine takes place in a fusion reactor around the fuel rods.

The Inlet for the Waterfall

The first piece to machine was the inlet for the reservoir. The inlet will have two G1/4 inlets for the return after cooling all the components. This is one of the most important pieces as it will create the waterfall running down the front face of the case.

6838893407_dba3c1a1f4_b.jpg
The inlet starts life as a large chunk of acrylic measuring 12x12x1.25". It was less expensive to buy a 12x12 piece of acrylic than it was to have it cut to size, strangely.

6838893447_2e1b7b2514_b.jpg
I cut out the 4x3" piece I need to machine using a bandsaw.

6838893499_5b9b82c2a4_b.jpg

6838893567_39dd5b65ce_b.jpg
Machining the piece to size.

6838893613_df5e18723a_b.jpg
Squared off edges machined in acrylic lead to eventual stress cracks. To prevent any stress cracks, I used a radius cutter that leaves a small fillet/radius around all the edges.

6838893671_731c1bb676_b.jpg

6838893703_322bec1a25_b.jpg
Machined out the pockets for the water flow.

6838893745_da56dbf430_b.jpg
Machining the holes to be tapped G1/4.

6838893795_87fc64098f_b.jpg

6838893835_5f6b1abb64_b.jpg

6838893891_572288b056_b.jpg
Finished inlet piece! If you look close, you can see the radius around the corner edge left from the radius cutter.

The Base

The base will hold the dual "fusion tubes" and the rest of the reservoir. It's machined out of a 1/2" thick piece of acrylic.

6838893939_3174c65261_b.jpg
Machining notches for the front and rear pieces.

6838893965_2dcc274358_b.jpg
Reaming the holes for the "fusion tubes" to 3/4"

6838893995_c298cc3564_b.jpg
Finished base piece.

I'm quite happy with how both pieces turned out this evening! Thanks for looking!
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Ametros X1
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