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-   -   Scratch Build Project: OSIDIAS - Carbon fiber SFF! (Temporary thread derail... Oct. 24th) (http://forums.bit-tech.net/showthread.php?t=188719)

craigbru 2nd Jun 2010 02:54

Project: OSIDIAS - Carbon fiber SFF! (Temporary thread derail... Oct. 24th)
 
Well, here it goes guys. After more than a year of planning, I've decided to officially to start Project OSIDIAS. Granted, I still have other projects I'm still working on, but I don't want to delay this any longer. I can't promise daily updates, but I have a feeling you all will keep motivated to keep my work as updated as possible.

OSIDIAS will take everything I've learned from my Rogue project, and double it, in both scope and ambition. I've got some pretty unique things I'll be attempting here, and I've got no assurances that everything will work out as I've planned. That doesn't matter though, as I enjoy the challenges of problem solving on the fly. Even though at this point, almost every detail of the case is planned, there are still going to be things I decide to change. However, due to the way the case is designed, there are certain things that must remain set in stone. The overall exterior of the case and the carbon fiber shell for example.

So, where do we begin? Well, for those that may not have been following along up until this point, this video gives the best project overview. If you've got 20 minutes to spare, this should catch you up to speed. You can also read up on my planning thread here.

Now, although this is the first official post of the project, I've only got a few pics to show you. Don't worry, I've got more incoming, but I this should get things started. :D

This case will be the first time I move away from aluminum as my primary construction material. There will still be plenty of it in this case, but I figured it was time for something more exotic. That's where carbon fiber comes in to the picture. Actually, carbon fiber, as well as a carbon fiber/kevlar blend. The carbon fiber will be placed around molds that I'm currently building, and them vacuum bagged. This is a proven technique for manufacturing, but the first time I'll be attempting it. There aren't many computer mods made from CF, let alone molded as in what I'm trying, but that's where the fun part comes in! I've got to give full credit to MKmods for his advice and input regarding working with carbon fiber. With any luck I'll not end up with a very expensive mess on my hands...

I mentioned having to make the molds, and that's where the following pictures pick up. Thanks to the help of my Romaxx CNC machine, I was able to accurately cut out a few pieces of the OSIDIAS core. These pieces will sit in the center, while an aluminum 'clam-shell' sits around it. After the carbon fiber and vacuum bagging, the idea is to push the center core out, and then remove the shell from the inside. This will leave a solid CF case, from which I will make the needed cuts.

Here are the blank pieces of MDF ready for the Romaxx CNC.

http://losias.net/projects/osidias/p...p4180312_0.jpg

After the CNC cut...

http://losias.net/projects/osidias/p...p4180313_0.jpg

http://losias.net/projects/osidias/p...p4180314_0.jpg

And finally, I've got a stack of them.

http://losias.net/projects/osidias/p...p4180315_0.jpg

Next up, we've got the core assembly!

disturbed13 2nd Jun 2010 03:27

subbd

Gtek 2nd Jun 2010 03:34

I just ordered some styrofoam blocks for my next project molds. But I chose the cheaper, fiberglass way...

good luck with CF!

shomann 2nd Jun 2010 04:13

I am with disturbed13. Subbed. I would double-sub if I could.

Good luck craig!

Boddaker 2nd Jun 2010 04:13

Awesome! Been waiting for your next project to officially start. I'm grabbing a front row seat this time! :D

Xtrafresh 2nd Jun 2010 04:22

http://gathering.tweakers.net/global/smileys/pompom.gif

The_Beast 2nd Jun 2010 04:33

Score, I can't wait to see more

hurv 2nd Jun 2010 04:42

I am psyched to see this happen!

stonedsurd 2nd Jun 2010 04:54

*subbed*

talladega 2nd Jun 2010 05:16

WOOOHOOOO!!!!!

craigbru 2nd Jun 2010 14:36

Quote:

Originally Posted by disturbed13 (Post 2320946)
subbd

Glad to have you aboard!

Quote:

Originally Posted by Gtek (Post 2320949)
I just ordered some styrofoam blocks for my next project molds. But I chose the cheaper, fiberglass way...

good luck with CF!

Thanks man! I think I'm more concerned about things like the resin drying properly than working with the CF itself. It would be costly if I screwed up, but that's part of why I'm making a mold I can reuse. Just in case...

Quote:

Originally Posted by shomann (Post 2320966)
I am with disturbed13. Subbed. I would double-sub if I could.

Good luck craig!

Thanks! Just sub on every forum in which I post. That should keep you busy for a while. :D

Quote:

Originally Posted by Boddaker (Post 2320967)
Awesome! Been waiting for your next project to officially start. I'm grabbing a front row seat this time! :D

Thanks Brian!

Quote:

Originally Posted by Xtrafresh (Post 2320969)

Quote:

Originally Posted by The_Beast (Post 2320975)
Score, I can't wait to see more

Quote:

Originally Posted by hurv (Post 2320979)
I am psyched to see this happen!

Quote:

Originally Posted by stonedsurd (Post 2320980)
*subbed*

Quote:

Originally Posted by talladega (Post 2320982)
WOOOHOOOO!!!!!

I appreciate the enthusiasm guys! This is what keeps me motivated and moving forward! :thumb:

Dark~3nergy 2nd Jun 2010 15:11

OH GOD OH GOD :worried:
i've been waiting for this for so long :D

good luck ! can't wait to see more

disturbed13 2nd Jun 2010 15:36

whoot
i was the first :D

sb1991 2nd Jun 2010 15:48

Sounds like this is going to be very impressive!

MrWizard 2nd Jun 2010 15:53

Honestly, I saw your name attached to a project log and just subscribed because it's the right thing to do.

craigbru 2nd Jun 2010 17:05

Quote:

Originally Posted by Dark~3nergy (Post 2321509)
OH GOD OH GOD :worried:
i've been waiting for this for so long :D

good luck ! can't wait to see more

Thanks! It has been a while, hasn't it?

Quote:

Originally Posted by disturbed13 (Post 2321549)
whoot
i was the first :D

Lol, somebody has to be. :D

Quote:

Originally Posted by sb1991 (Post 2321566)
Sounds like this is going to be very impressive!

Thank you! I try and aim high. The fun part is trying to live up to my crazy ideas.

Quote:

Originally Posted by MrWizard (Post 2321576)
Honestly, I saw your name attached to a project log and just subscribed because it's the right thing to do.

Haha, thanks for the kind words.

So, are you guys ready for another update?

My last post left off with the cut MDF pieces for the core of the case. What I needed now was some simple way to fasten those pieces together, while still providing strength. I went round and round with possibilities until I decided on the following method. It all started with a trio of 22mm holes courtesy of the Romaxx.

http://losias.net/projects/osidias/p...s/p5310350.jpg

Thanks to the CNC's accuracy and repeatability, I ended up with 6 pieces just like this.

http://losias.net/projects/osidias/p...s/p5310351.jpg

With the first piece laying down, I tapped 3 sections of PVC pipe into the holes. The fit was just tight enough that there was no movement once in place, but taps with a hammer could still allow any needed adjustment.

http://losias.net/projects/osidias/p...s/p5310352.jpg

Now finally, here is the assembled core. It's lightweight, yet very strong. The PVC pipe not only serves to hold the structure together, it also has a secondary purpose. Since the carbon fiber will be vacuum bagged, the pipe will allow for pressure equalization between the front and rear of the mold.

http://losias.net/projects/osidias/p...s/p5310353.jpg

With the core done, I'll be moving on to the 2 part aluminum shell that fits around it. Thanks for reading!

shomann 2nd Jun 2010 17:15

I just realized that I DID double sub ;) (For those that don't know, Craig maintains his own forums)

Incidentally, you don't have to ask if we are ready for another update Craig - we are, even if you post them every hour ;)

voigts 2nd Jun 2010 17:42

This looks like it is going to be a fun show to watch. :jawdrop:

Fabou 2nd Jun 2010 18:13

Since everibody seems so excited I join the fun. Great start.

Blooddrunken 2nd Jun 2010 19:15

This will be fun and I'll be watching! :thumb:


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