Project: OSIDIAS begins!

[CorrodedZoul]

craig, this is an awesome project, +rep & +sub!!!
Wish you best luck with this!!!!!!

[craigbru]

Wow, this looks ambitious just watched the walk through video & read up to now, action packed super fun happy box it looks like , I'm gonna enjoy watching this progress , keep up the awesomeness Craig . +rep here & on bit-tech

Lol, thanks Waynio!

craig, this is an awesome project, +rep & +sub!!!
Wish you best luck with this!!!!!!

Thanks man!

Ready guys?

Well, working with the carbon fiber was an interesting experience. I got completely prepped and ready to go last night, so that I could start wrapping first thing this morning. I'll admit to being a bit nervous. I didn't have any room for error, and with my OCD about having things perfect, the pressure was on.

I woke up this morning, headed to the shop, and cranked up the music. A little Zune Pass with Breaking Benjamin as the starting point, and things were underway! What you'll see here is the mold ready to go, with the carbon fiber strips sitting on a tube right behind it. This would allow me unroll the CF onto the mold with minimal handling.

It was now time to mix up the resin. I was using a marine grade clear epoxy with a 109 medium hardener. This stuff has a pot life of about 30 minutes, so there was no time to do anything but get underway. With the resin mixed I was on the clock. I slipped on my rubber gloves and hit the mold with a layer of resin from a 4" lint-free roller. The first layer of CF was on soon after.

I continued wrapping and rolling, taking extra care not to deform or stretch the CF in any way. I also had to be sure that all the corners had the fiber nestled in them without issues. I thought I was making good time until I went to apply a little more resin, and the roller started to pull up on the CF. Crap! That meant my resin was hardening. Had it really been 30 minutes already? Well, it didn't matter. I couldn't do anymore at this point. I needed to wrap peel ply around it and get it bagged. I still had one layer to go, but there was no way I could get it on without causing serious issues. So, bag it, I did...

I smoothed the bag out a little and left it under vacuum for about 2 hours.

Now, aren't you all excited to see what's next? Yeah, I am too, but I had to head out of town for the rest of the weekend. The next update will likely be late Monday or Tuesday night.

So, overall, the experience wasn't as bad as I thought it might be, but I was cutting it close with the resin cure time. I also know I'll have a few ridges in the resin from the bagging process, but that's really not an issue right now. I can sand and add more resin. In addition, I'll likely go ahead and add the last layer of missing fiber. I'll update early this week guys!

[SXRguyinMA]

nice work! can't wait to see it unwrapped! And good choice on Breaking Benjamin If you like them check out Crossfade, those guys are awesome

[x88x]

Nice! Bad luck on the resin though. Will you be able to go back and put on the last layer later?

Also, question about the bagging process. Everywhere I've seen CF done before requires crazy high pressures and thus expensive machinery. Does this process create as strong a composite as that? I'm thinking over some projects I have planned long-term, and if this creates anywhere near the strength of high-pressure setting...

[craigbru]

nice work! can't wait to see it unwrapped! And good choice on Breaking Benjamin If you like them check out Crossfade, those guys are awesome

Thanks man! I do have some Crossfade in my playlist, along with Evan's Blue, Cold, deftones, Seether, etc. I'll either use the Zune Smart DJ or Pandora, and I've always got a great mix of tunage.

Nice! Bad luck on the resin though. Will you be able to go back and put on the last layer later?

Also, question about the bagging process. Everywhere I've seen CF done before requires crazy high pressures and thus expensive machinery. Does this process create as strong a composite as that? I'm thinking over some projects I have planned long-term, and if this creates anywhere near the strength of high-pressure setting...

Yes, it was a little unfortunate, but it's fixable. It just means some sanding and filing is needed. I need to get the surface perfect before the last layer of CF goes on. Even if I couldn't put the last layer on, what I have is cosmetically fine. It's just a resin issue, and that can always be fixed. Things like wrinkles in the CF couldn't be.

I'm not sure high pressures are needed for an application like this. The little test piece I made last week, was crazy stiff, and it was only 5 layers. I'm certain this is much stronger than aluminum, and it won't deform, it will flex and deflect.

[x88x]

It's just called 'carbon fiber bagging', right? I'll look into it some more...it would definitely be worth it if it works.. For context, the application I'm thinking of is for the monocoque or frame of a few different vehicle ideas, ranging from <100lbs to maybe half a ton. (Waiting on me having a garage and more expendable income...like so many other project ideas..)

[craigbru]

It's just called 'carbon fiber bagging', right? I'll look into it some more...it would definitely be worth it if it works.. For context, the application I'm thinking of is for the monocoque or frame of a few different vehicle ideas, ranging from <100lbs to maybe half a ton. (Waiting on me having a garage and more expendable income...like so many other project ideas..)

Yes, bagging or vacuum bagging. Wow, you're application would be a little more heavy duty than mine. I'm not sure what your results would be on such a large scale.

Anyway, I apologize for not updating last night guys. I've been struggling with a pinched nerve in my neck, and subsequent pain in my right arm. It was really bad yesterday, and I didn't even make it down to the shop. I'll be having an MRI done tomorrow, and likely have a surgery in my future. It sucks, but I'll keep plugging away. Despite being in a little pain, I'm gonna show you the CF. What you are looking at is the final layer of fiber needed on the case. I'll have to lightly sand a few small air bubbles, but otherwise it's cosmetically pretty darn good. I'm also going to apply one more layer of resin before I remove the mold. I want to be sure the CF is well protected from damage. It's a whole lot easier to sand and fix resin than have a blemish in the fiber itself...

[x88x]

Mmmm, that is pretty.

[silverdemon]

looking very nice! keep up the good stuff!

and let's hope the neck/arm-thing is not too bad...

[craigbru]

Mmmm, that is pretty.

Thanks. It did turn out as well as I'd hoped.

looking very nice! keep up the good stuff!

and let's hope the neck/arm-thing is not too bad...

Thanks man.

Yeah, hopefully I can get the pain sorted, because it's a constant distraction.