Project: OSIDIAS begins!

[Kayin]

Any CF fabric left over? I have a project in mind, and it needs just a bit of CF fabric... LMK, or let me know where you got yours.

[craigbru]

Sad to hear there's a short delay, but when you make such a case you'd better make it perfect.
Like you said, you will always look at it and think that it's not good enough (for yourself) if you don't fix it

That being said, I really like this case already!

One other thing The edges you cut of probably contain some sharp edges and maybe splinters. If you cut yourself or have a splinter in your hand or other body part you should really take it out immediately. I heard that carbon splinter will grow INTO your body (whereas metal or wood will grow out) When it reaches you bones and can not grow any further it will start to rot and leave very nasty internal infections...

Thanks!

I've only gotten a few minor slivers, and they were removed immediately. Luckily they are black and easy to see.

Any CF fabric left over? I have a project in mind, and it needs just a bit of CF fabric... LMK, or let me know where you got yours.

How much are you looking for? I've got a few small pieces. One is only about a foot square, and I think the other is maybe about 10" x50". If you need more than that, I got mine on ebay from elitemotoring.

[Kayin]

Will PM you. Thanks for the info!

[craigbru]

Although it's not quite as large an update as you all were expecting, I did manage to get a few things done over the weekend. A lot of people have questioned why I wanted to bother sanding down the case and adding another layer of fiber. Well, I've got a few pics that can hopefully show you in more detail why I wasn't happy. At this point, the case is sanded and ready for it's last layer of CF. It's nowhere as pretty as it was before the sanding, but that will be remedied soon. Trust me...

Now, here is the best way I can show you the before and after examples of the 'rounded' edges I was speaking of. This should make things pretty clear. This is a before pic, taken of the excess I cut off of one of the ends...

Now take a look at the after. You can see there is no more rounded edge, and I'm much happier.

Okay, now with that out of the way, it's time to move on to the side panels. I'll be working on them until I have more regular CF arrive to finish the case itself. As you are about to see, making the molds for these panels is a whole lot easier than before. Two bends and I was golden. This nice piece of aluminum will be the basis of what is to come.

A few bends later...

Now I've just got to get the CF/Kevlar blend cut to size, and I can get the fiber laid down. Hopefully tomorrow!

[x88x]

Nice. I like the look of that blend.

[craigbru]

Well, I've got a little more work done on the side panels. I'm using the same molding process as the case, but it's nowhere near as complex this time around. Here is the Kevlar/carbon fiber blend laid out and ready for marking... Isn't it pretty?

I've marked out the fiber, and am making my cuts here. This stuff truly sucks to cut. Even with a specialty shears, it has a tendency fray and not cut cleanly. I wouldn't ever attempt this with regular scissors. I would imagine you would slit your wrists in frustration.

Now finally, here are 5 layers of fabric freshly removed from the vacuum bag. I've still got plastic peel ply on it, but that will come off tomorrow. I'm going to sand a little, and add one more layer of Kevlar. The same procedure I used on the rest of the case, should get me pretty good results. The trick will be in finding the perfect piece of fiber for the top layer. The weave on this blend is very sensitive, much more so than with regular carbon fiber. Every little flaw or misalignment seems magnified 10 fold. I'll manage though... or go insane trying!

Tomorrow I'll get the other panel started, and sand this first one. Then I've got to get an end mill or two ordered for the Romaxx CNC. I'll be using it to cut out the side panels. I'll do a few test runs first, since I don't want to screw one of these up. Mistakes would be costly...

[Loki]

Nice... really shiny fabric... Can't talk.. I'm dripping drool XD

[x88x]

That panels looks awesome! Did you make it a bit larger than it'll need to be? I'm just wondering how you're gonna handle the tape on the edges.

[craigbru]

Nice... really shiny fabric... Can't talk.. I'm dripping drool XD

Thanks man!

That panels looks awesome! Did you make it a bit larger than it'll need to be? I'm just wondering how you're gonna handle the tape on the edges.

Thank you. Yes, the panel is bigger than it needs to be on all sides. I'll have to cut it down after the last layer of kevlar is on.

[craigbru]

If it weren't for pictures like the following, I'd take the Kevlar/CF blend, and make it disappear... Yes, it's a royal pain to work with. I knew it would be, but until you are actually working with it and trying to make it do what you want, you have no idea...

It doesn't like to cut cleanly, no matter the process. The Kevlar fibers really have a mind of their own. I've found that I get the best results if I start cutting with a metal carbide cutting wheel. That cuts quickly, but not cleanly. I then followup with a reinforced cutting disk. This cuts much more cleanly, but it's slow. I can't take much material off with each pass. After that, I use a file to straighten the cuts. Then finally, I finish up with a 320 grit wet/dry sand paper. This does a decent job of cleaning the edge up, but it takes a light touch. So, that's one heck of a process for a single cut!

Time to cut! I used a yardstick as a straight edge, and followed up with my line taping method.

An hour later I had two sides done... This is gonna take a while. Lol.