Scratch Build – In Progress Project: OSIDIAS - Carbon fiber and 3D printed SFF (Jan. 2, 2020)

Well, I think it would have been fine if I had got it bagged sooner. Honestly, it's not bad, but it's just enough to bother me. Adding more resin wouldn't change the round look of the CF under the resin, regardless of how much was added. The only real solution is to get things perfectly flat and squared off on the existing case, and then add one more layer. Looking back, I should have done that before I added the current 'last' layer.

It's also most noticeable on the top of the case. After I point it out, it should become more obvious what I'm not happy with. Take a look at the top corners of the case in the following pic. See the roundness? I can't live with that, so I'm gonna fix it. My perfectionism will not allow for anything else.

 

How about a 'sandwich-style' mold?

Disclaimer - I've never a cast a thing in my life.

 

Well, that would technically work if you could get the sizing right. I'd hate to attempt it on a case like this though. My approach is working, but it's a learning experience. Now that I've got it figured out, I should be able to nail the execution on the rest of the case. I'm going to get really creative on the interior. Complex molds and more fiber! I've decided to ditch a lot of the parts that were previously aluminum.

 

Lol, I do not know exactly what you mean. Is it the radius of the two top corners? I agree it would be cooler if it was the same as the other corners, but it didn't look that odd to me.

By the way, yesterday I was reading the planning thread of this build, its going to be epic!

 

I dunno, I kind of like it like this with the little curves.
But Its your mod and your OPD (obsessive perfectionism disorder).
So I'll watch (and not admit that I would prefer you leave it like this so we can see whats next )

 

You vaccuum sealed the CF, so there must not have been good adhesion on the corners that turned out Rounded verus flat??!!!

What do you think Caused this to happen??? I mean a Vaccuum seal is pretty strong and should have held the CF down on those corners!!!

 

In your mind, picture looking at the sheets side on. As you lay each successive sheet on
the radius MUST increase, assuming the thickness of each layer of CF remains the same.
Even using the opposite form, it would be difficult to pack each successive layer into the
corners. You can try this with sheets of paper. One sheet will give you a reasonably sharp
corner but as the number of sheets increase the corners get 'rounder'. The pressure of the
vacuum bag would have been distributed evenly around the radius.

By the way, it looks great to me. Nice work Craig.

 

Yes, it's the radius of the top two corners. It's overall not as sharp as I'd like. It may seem minor, but dang if it didn't start to bug me yesterday...

Thanks!

Haha, I figured I might be alone in my little nit-picking... I'll makes sure you guys still have progress to look at. The side panels should be fun.

Oh, there's excellent adhesion. The problem was that when I wrapped the first layers, the resin started hardening on me before I was done. By the time I got the bag on and applied vacuum, the resin was too stiff to 'suck' down there as much as I would have liked.

Yes, I knew my corners would get more rounded as I applied more layers. It's just one of the effects of using a molding process like I did. I actually want a small radius at each corner, but I just didn't like one as big as I had. If there were more than a cm between the corners on each side of the top, maybe it wouldn't have bothered me so much. The corners on the bottom of the case I was fine with. Damn OCD...

Thanks though, I appreciate the kind words!

 

Just read through as much as I could. This is another project I would be following closely. So far this looks very good. Keep it up Craigbru. Can't wait till the next update.

 

I'm looking forward to seeing this done, has anyone used carbon before on here?

 

Yes.

 

Thanks shah! I'll try to get an update posted tonight.

Yeah, there have been others that have used it, and just so I don't exclude anyone, just go ahead and do a forum search. You'll come across some more cool projects. That said, I don't recall anyone using it in a mold like I have. I'm getting old though, so maybe my memory is fading...

 

@boscoe - There's one that was a Mod of the Year contestant. Since I don't remember the name, that's the fastest way to find it. 2007 I think...

I avoided pointing out the corners were uneven because I knew you'd try to fix them. I should have known a perfectionist would have noticed already.
-Making the core one peice CF = If you need to make any of it removable, you can embed nuts into the material.

 

Lol, it's actually easier to make out the issue in the pictures than it is in person. The depth of the CF in person makes it a whole lot harder to notice. Either way, I have to listen to that voice in my head. A few days ago when I said I was 95% happy with the case, I couldn't get the 5% out of my head. No worries, as I'll get it straightened up.

If the core is a single piece, I'll have to pull off a molding masterpiece. I'm still undecided as to if I should go that route, or make it in 3 pieces. I'm not worried about the complexity, so much as I am about future changes. A single piece becomes very limiting. I'll have to ponder that a bit...

 

As others have mentioned, I can understand that it bugs you and it isn't the way you want it, but I personally like the look. I think it looks really sweet. I have no problem with a bit of variation in the curvature as to me it ads character and doesn't detract at all from the look.

 

I think the biggest reason it bother me, is the fact that the top two corners of the case are 45 degree angles, just as the top of the side panels are. There should be a parallel plane in transitioning from the case to the side panel, and there's not. It would go from the angle of the side panel, to a rounded surface, and that just doesn't seem right to me. I don't know if I'm explaining it well, but it all makes sense in my head.

 

Damn it!!! Dont' be giving him ideas that's going to slow this process any more! What the hell were you thinking!!!!!!!

 

Lol, it is a good idea.

 

First off, sorry for hijacking the thread some what here, but I do have a few questions and you are likely the best candidate to answer the questions and if any one else plan to do work with CF I think they would have similer questions, hence why I didn't PM.
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1. I've been thinking of doing CF and plan to place the order by the end of the month (Graduation money Cheesecake!). I plan to buy 2-3 yards of this: http://cgi.ebay.com/Carbon-Fiber-Cl...tem&pt=LH_DefaultDomain_0&hash=item1c0be76d66 for a mod that I'v been meaning to do for a while now. Any thing against that particular CF cloth?

2. I plan to buy this resin + hardener kit: http://www.fibreglast.com/product/Clear_Gel_Coat_just_gel_coats_00180/Gel_Coats .One Quart w/ hardener 180/69-A for $36.95. That should be enough for a surface area of ~1248 square inches (one layer of CF only)?

3. Would you happen to know if adding pigment (such as this: http://www.fibreglast.com/product/Black_Pigment_43/Pigments_Glitterflake ) ruin the CF look? The reason is, depending on cost,etc I may use the epoxy I use for Fibreglass which has a yellowish tint and mixing the pigment should offset that correct? Would that mess up the CF (mainly concerning the "looks", I don't care much for strength for this)?

4. What resin did you use?

5. I'm pretty sure this is the wax you used: http://www.fibreglast.com/product/Parting_wax_1016/Mold_Releases . Did you also use the PVA spray with it?

6. Any more tips/hints,etc?

 

Yes, for example: http://www.bit-tech.net/modding/2007/12/20/carbon_li/4