How to build a CF box ?


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Jess8bit
Jess8bit
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Again, I find it a good idea in making the part twice longer then cut it in half afterwards ! Neat cutting indeed is a matter of concern.

I would probably go with resin infusion, with a layer of gel coat as first layer which command me to prepare the wood surface (but I'm still afraid not to have a perfect cosmetic finish, which is the purpose, as you guessed). Maybe I should think about making a glass fiber mould from the wood part, then sanding the mould to the perfection, then proceed to resin infusion for making the final part. I also thought about finishing the part with a clear coat on top of gelcoat (once the part is demold).

The matches box was only an example. What I'm looking for is the best practrices for maknig box-shaped pieces in general. When you know how to do one, you almost know how to do any type of CF boxes Smile

Thank you for all your precious inputs (and sorry for my rough "french" english :-p).
Edited 12 Years Ago by Jess8bit
brasco
brasco
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hmmm
i think one could use wood (a 90 degree joint)and make a section longer than what you need. if you make it
 longer then you can cut it in half and that way you have less laying up to do. you could
 make the wood wider for vac bagging or just lay it in and brush and roll the CF. if you do
 the latter it is a good idea to get or make a vacuum chamber to degas(remove air bubbles)
from your epoxy mix.
 i have been reading up on ways to cut it after and the cutting tools for tile that cut wet could
be useful for clean cuts and dust control.

what are your appearance needs for this project? just making it is one thing, but making it
to a high quality cosmetic finish may take some time and experience. if the box is good but not up to
expectations in appearance you could sand it smooth and then cover it with self adhesive CF veneer
or CF pattern vinyl wrap. i assume the ends of the tray part and the larger box/tube section needs to
look good. and the bottom of the box? maybe not such high cosmetic standard. the CF veneer can also
 cover any joint lines as well. the vinyl could fix all appearance issues if need be.


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Jess8bit
Jess8bit
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Thank you Brasco for the idea of bonding 2 L-shaped panels Smile and for the interesting links about adhesive bonding.

So the secret for making CF boxes would lie in the bonding experience... indeed ! It's a good start for me, so thank you again Smile

What materials would you use to make L molds then ? That may be a newbie question ^^ but I really wonder which the best way to make right angles panels.

regards

brasco
brasco
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hello
i have been reading that molds with 90 degree angles can be hard to make the release happen. yes parts can be flexy and strong but if it cracks out you will be out the part and the cost of materials. and your time.
if the angle is 90 or less it can mechanically lock and be very hard to get loose from mold.
what do you think of two L shaped molds that can be bonded together and then add the ends for the tray portion?
there are limits to mold making and the complexity of the part.

joint construction

more on adhesive joint construction

pre made parts to use??

not sure if my limited knowledge can be of more help.

good luck Smile


scott


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Edited 12 Years Ago by brasco
Jess8bit
Jess8bit
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Hello everyone, happy new year ! I whish you many successful composite projects Smile

I wonder what is the best way to build a box in CF, with 4 or 5 sides. The example I have in mind is a typical matches box, both the outer box (where you scratch the match, which is 4-sided) and the inner box (the drawer, where are the matches, which is 5-sided).

What kinds of moulds or plugs to prepare ? How to make perfect 90° angles ? how to bond sides ? Which process (Resin infusion ?) ? Does it require inner reinforcement (like a flat angle bracket) ? Do I need to make the 4-sided  in one pass (with one cloth) ?



Thanks for sharing ideas guys Smile
GO

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