Transcript Fiberglass Chassis Cover 101

Fiberglass Chassis Cover 101
Why
• custom shape
• lightweight
• strong
Why not
• time consuming
• detail oriented
• can be costly
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Develop the Design
• Develop design in CAD
• Verify size
• Print plan views with grid overlay
Create the Plug
• Layout slices of shape on blue
styrofoam
• Plug is the same size as the final shell
Shape and Assemble Pieces
• Use bandsaw to cut shapes
• Glue pieces together with styrofoam glue
• Assemble as giant puzzle-pieces
Cover with Bondo
• Mix only what you can use in 3 minutes.
A large flat board is better than a bowl for
mixing; use broad putty knife to mix.
Be thorough. Clean tools immediately
with acetone.
• Use good ventilation
• Cover with flexible spatula-type tool for
smooth, even application
• Allow to harden
Preparation of Mold
• Sand with long, straight sanding block
or sander
• Use mask due to dust
• Fill low spots with Bondo
• Re-sand
• Prime and sand until smooth
• WAX or SPRAY with RELEASE AGENT
(many times!)
Lay Up the Fiberglass Mold
• Use chopped fiberglass mat for mold
• Cut all pieced to size first
• Use Epoxy Resin (strong/light/odorless/expensive) or
• Polyester Resin (strong odor/cheap/heavier)
• Mix resin in quantities useful in 3 minutes
• USE LATEX GLOVES
• Wet pieces with resin before applying (use alum cooking tray)
• Dab resin into all layers of fibers with short paintbrush;
be sure to push out all air bubbles
• Allow layer to set up before applying next layer
• Dab in resin as above (try to use the same brand of resin;
right front corner was different brand here)
Release the Plug
• Once resin is hardened, release
styrofoam from mold
• May need to ’help’ release where drafts
(reverse angles) are too steep
• Be prepared to remove styrofoam in
any way possible if fiberglass does not
release from release agent
Lay-up Shell
• Test mold for fit
• Fill any inside imperfections
• Apply release agent to inside
• Use Fiberglass CLOTH for
shell
• USE LATEX GLOVES
• Cut all pieces first
• Wet cloth by dipping, then
apply as in previous step.
• Remember to push out all air pockets.
• Reinforce at pressure points, edges and holes
Inner Mold
• Remove shell carefully
• Sand as needed, with fine-grit sand paper, then steel wool
• Paint with spray-on autobody car paint
• Lightly spray first coat
• When tacky, spray heavier layers
• Continue adding multiple layers for high sheen
Finish
• Add detailing & graphics
• Total time: evenings,
for 2.5 weeks (25 – 30 hrs)
• Total cost, including learning
curve (additional materials):
Comments? Questions?
Contact Muncie/Delaware FIRST Robotics
Team 1720 – The PhyXTGears
Mike Koch, Engineer/Lead Mentor
[email protected]
(765) 661-5562