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Production level molding
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
Posts: 381
City: Stockton

PostPosted: Apr 23, 2010 6:54 pm    Post subject: Reply with quote

I mixed this batch a tad hotter, I like to at 1% for the first layer to avoid orange peel, but on the second coat I went to 2% of catalyst.
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: Apr 23, 2010 6:59 pm    Post subject: Reply with quote

And the second coat. It's built up to about 1/16 of an inch at this point.
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b33nine
Soul Rider
Soul Rider


Joined: 04 Sep 2008
Posts: 311
City: Salem-ish

PostPosted: Apr 29, 2010 12:24 pm    Post subject: Reply with quote

I love watching these threads of you building these things. I wish I had the time and the know-how because I can imagine it's a fun process.

If you knew of a way to do graphics on the board by printing them on somehow I'd love to try and work out some kind of swap with you Mr. Green
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Ladies Man
Ladies Man


Joined: 03 Mar 2008
Posts: 10056
City: Edmond

PostPosted: Apr 29, 2010 12:43 pm    Post subject: Reply with quote

Looking good! Another great write up...I'm enjoying following along.
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
Posts: 381
City: Stockton

PostPosted: Apr 29, 2010 1:21 pm    Post subject: Reply with quote

Thanks guys - I have a ton more to do on this, but I threw my back out over the weekend and all I can do is sit on the sofa with a heating pad! I hope to get back to it in a day or two...sitting on my a$$ is driving me insane.

b33nine - print like a color printer? Most laminates for logo's and such on a surfboard are done on rice paper - color ink jet on the rice paper and it shows up like it was painted on. Talk to me 'bro, what can you do?

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b33nine
Soul Rider
Soul Rider


Joined: 04 Sep 2008
Posts: 311
City: Salem-ish

PostPosted: Apr 29, 2010 1:55 pm    Post subject: Reply with quote

I work as an illustrator and a game artist. I like to think that I can do most anything.

here's my website with some of my work, but it's certainly dated and aimed at a particular audience: http://brandonleachart.com
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
Posts: 381
City: Stockton

PostPosted: Apr 29, 2010 7:08 pm    Post subject: Reply with quote

Gorgeous work! You rock, PM me, please.

I threw my back out last Saturday and went in to the shop to find my flages curled up. Polyester shrinks like a bad cotton T-shirt.

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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: Apr 29, 2010 7:18 pm    Post subject: Reply with quote

I'm going to make two pieces of ply to outline the board and hold the flanges down while I glue them to the parting board. I don't have a piece of ply big enough to cover everything, so I'll make two pieces...split down the centerline.
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Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: Apr 29, 2010 7:23 pm    Post subject: Reply with quote

I mark the centerline and then the outline, but you'll notice that the ends of the outline are adjusted some
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Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: Apr 29, 2010 7:28 pm    Post subject: Reply with quote

Then, I jigsawed the shape out. I'll smear some glue down under the flange and on the parting board - then clamp it down until the glue dries. Once that has dried, I'll go back to finalize the last gel coat and then start the fiberglass lamination.
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Soul Rider
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Joined: 21 Oct 2005
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City: Stockton

PostPosted: Apr 29, 2010 7:31 pm    Post subject: Reply with quote

You may remember at the beginning, I mentioned leaving a gap around the edge for "clamping" it came in handy here! Smile I can use smaller clamps and position them easily.
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b33nine
Soul Rider
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Joined: 04 Sep 2008
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City: Salem-ish

PostPosted: Apr 30, 2010 7:26 am    Post subject: Reply with quote

PM sent Very Happy
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 12, 2010 6:58 pm    Post subject: Reply with quote

Finally back to it! I laid a thin bead of glue down between the flange and the parting board. I then clamped the plywood cut out on to it.
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 13, 2010 5:54 pm    Post subject: Reply with quote

The flange on the right hand side is stuck down and "mostly" flat, and so I' repeat the process for the left side.
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RHB
Newbie
Newbie


Joined: 17 May 2010
Posts: 14
City: Cleveland

PostPosted: May 18, 2010 6:14 am    Post subject: Reply with quote

Nice work guys...that looks solid!
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surfdad
Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 19, 2010 7:28 pm    Post subject: Reply with quote

One last layer of gelcoat and tomorrow it will ready for the CSM - first a layer of light 3/4 oz CSM.
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Soul Rider
Soul Rider


Joined: 21 Oct 2005
Posts: 381
City: Stockton

PostPosted: May 22, 2010 9:36 am    Post subject: Reply with quote

Back to it. The next step has a ton of stages, but they are all basically the same. I apply a layer of chopped strand mat, then wait 24 hours to do the next layer. A mold can NEVER be too stiff or strong, so I'll be laying up probably 6 or so layers of CSM.

The first layer down is the 3/4 oz CSM, because it conforms to the shape easily and also wets out easily.

Subsequent layers will be a hevier 1.5 oz CSM and I also have some 3 oz that I'll apply.

For this first layer of 3/4 oz, I mixed up 20 oz of resin in two batches. I kick the first batch a little cooler and the second batch a little hotter so that I can accomodate my working time.

Photos of the process:

The csm laid out, not measured yet.

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Soul Rider
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City: Stockton

PostPosted: May 22, 2010 9:39 am    Post subject: Reply with quote

CSM cuts very easily, it's just random pieces of fiberglass pressed with a binding material. I have cut the general outline of the mold, including the flange. I won't worry about being too "neat" at this stage as I'll just grind the flange smooth.
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Soul Rider
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Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 22, 2010 9:44 am    Post subject: Reply with quote

This picture shows the supplies and tools I'll be using.

Mixing cups, roller, squegee and stiple brush. I pour the batch of polyester resin directly on the csm and then spread it quickly with the squegee. While it's still "puddled" I use the roller to push the resin into the mat all over. Finally, the stiple brush is used for tight areas and any dry spots that I'm having trouble wetting out. The csm and polyester resin will attach itself to the polyester gelcoat.

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Soul Rider
Soul Rider


Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 22, 2010 9:47 am    Post subject: Reply with quote

No job is done until it's cleaned up! I toss my tools into this ammo box filled 1/2 way with acetone. The seal on the lid keeps the vapors in and makes quick and easy work of cleaning off the polyster from the roller
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Soul Rider
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Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 22, 2010 9:49 am    Post subject: Reply with quote

As mentioned earlier, I measure out two 10 oz cups of resin, reserving one a tad hotter to finish up the wet out.
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Soul Rider
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Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 22, 2010 9:52 am    Post subject: Reply with quote

It's a little tough to see, but if you compare this picture with previous pictures of the gelcoat you can see the matte finish below, that is the wet out csm first layer on the mold.
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Soul Rider
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Joined: 21 Oct 2005
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City: Stockton

PostPosted: May 22, 2010 9:53 am    Post subject: Reply with quote

Tools into the ammo box and acetone.
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