Scratch Build – In Progress Project: Evolutionary

Ok the thing is ready for sawing.



Here we go.





The last bit has to be done outside the sawing mold.



Almost ready.

 

Really nice, Did you sanded the circle with hand?

 

Wow impressive works

 

That really is some great work Franklin !

 

Very nice work.

 

@ Nsonic: yes it's done by hand.

I tried to make the first polyester airintake, but I had some problems. The shape was to difficult to make this way. I have a solution but that needs to be painted three times with the polyurethane again. I'm sure the problem is solved, so you can expect a photograph off an polyester airintake this week.

Just to give you an impression of what it will look like I Photoshopped a picture from the mold.



So this is what you will see on the left and right side from the case.

 

Nice work franklin, thx for the reply

 

After the small problem I'm ready to give it another try.



Time to put on the latex gloves again and mix the resin. I used more layers of fiber glass this time, because it has to be much stronger this time and the outside isn't important, because this polyester part will only be the mold that I will use to make the final product. I need a negative.



It's important that the polyester part is a perfect negative of the MDF mold. So I used a MDF disk to push the fiber glass in the corners and keep it there untill the resin is cured.



Just before the resin had cured I pulled out the disk with the hook. I had some problems this time getting the polyester off from the MDF mold. Drilled a hole in the middle to let the air in, but that wasn't enough to do the job. My old man had a great idea, put the mold with the polyester in the freezer and yes it worked The polyester came of without any problem.



This is the final mold I need. This polyester mold I will use to create the four intakes.

 

that mold looks pretty sweet, good job!

 

very nice.

 

Good job Franklin. Heat and cool are good things to remember when things are tight, well done!

 

Well it's quite a beast, but one of precision engineering. I've always been a fan of the ducting, no pun intended. Keep it up and it'll be a cracker of a case.

 

I had to adjust my plans slightly. It was to difficult to use the negative as a mold, so I will use the mdf mod. This means I will have to spend more time to give the surface a smooth finish with polyester bondo and sanding. No big problem.

I started with drawing a shape on paper. This is the shape I need to cut from the fiber glass. Put the paper on top of the fiber glass and mark it.





Cut it out three times, because I need three layers.



and ready for use.



The mdf mold is waxed and ready to be used again. First apply some resin on the mold. When the mold is waxed in the right way, the resin seems to try pulling together and form some kind of drops. This is good, because it means the polyester will come off easier later on.



Put the first layer over the mold.



Applied the resin in the middle.



With the tip of the bruh I tapped the resin onto the fiber glass. Tap, because you want the remove any aitbubbles underneath the fiber glass.



To prevent the fiber glass coming loose again, when tapping the outside of the mold I used some kind of plug. Also made from mdf and also treated with the molding wax.
The plug is slightly smaller then the hole, this because the lauyers of fiber glass will need some space ofcourse.



Working from the edge on top of the mold, down to the bottom of the mold.



It's easy to see when all the fiber glass is soaked with resin.



Time to take out the plug and repeat the whole processa another two times.
I will have to sand the intakes and apply one more layer of surface tissue. This because it will be easier to smoothen the surface. Right now the intakes look like this, a bit rough but that will change in a couple of days.



I will remove the orange area. Some sort of fingerguard will be placed in this opening later on.

 

evolutionary work dude!

 

WOW. Love your fiberglass work. Been following this on another forum but things are much more exciting over here. Keep it up

 

Nice work Dude

 

Im amazed at all the work u are puting in to this project,i also love the fact that u are making all the parts by yourself since i know how much more work that is than buy ready-made parts.I cant wait to see this scratch build finished.

 

After sanding the polyester intake it already looks a lot better. I sanded the part with sandingpaper grid 400 and I will have to sand it further with sandingpaper up to 1200. Also started making a paper model from the guard that will be mounted inside the opening of this intake.



It will be made from white frosted acrylic and it will be mounted somewhat deeper then the paper model.

 

This mod is the one I anticipate most, it looks very good so far.


H.B.

 

wow, i love what you are doing here. it looks absolutely fantastic.