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View Full Version : 3 10's...ported...fiberglassed...pic



joeldirt
09-04-2005, 07:38 PM
this is just a pic in the begining stages. This is only the face of the box. The total volume will be aproximately 5 ft3. using four 3" ports tuned to 35 hz. the face what you see here, is going to be painted gloss black. the box it attatches to will be grey carpet. Blue LED's will emit thru the ports from inside. This will be an ongoing log, so look on for future pics as I update. Sunday hawaii time as of now... 1:47 pm. I started this morning at nine. [img=http://img198.imageshack.us/img198/5165/310sglassed1sy.th.jpg] (http://img198.imageshack.us/my.php?image=310sglassed1sy.jpg)

Mr. Opportunist
09-04-2005, 07:45 PM
looking good...

ruckus
09-04-2005, 07:53 PM
they gonna fire up like that or is that a side view?

saywhat?
09-04-2005, 08:00 PM
http://img198.imageshack.us/img198/5165/310sglassed1sy.th.jpg

joeldirt
09-04-2005, 08:02 PM
they gonna fire up like that or is that a side view?

that is a side view. they will lay flat with the cones facing you as you look in from the outside. the size of this box is designed for large trunks or SUV's. I can make the boxes that go behind these much smaller depending on the calibur of sub, and the size of the trunk area. This pic is a mock up for the mold I am going to be making of it to make replica after replica. This one will be painted, however each cast I make from the mold will be used allong with a colored gell coat. so I shouldnt have to sand anything what so ever out pops from the mold a perfect finished piece. Next one will be for two twelves, and two tens. I will eventually make one for two fifteens as well.

joeldirt
09-04-2005, 08:05 PM
http://img379.imageshack.us/img379/6480/310sglassed0049cv.th.jpg (http://img379.imageshack.us/my.php?image=310sglassed0049cv.jpg)

http://img379.imageshack.us/img379/2632/310sglassed0013ni.th.jpg (http://img379.imageshack.us/my.php?image=310sglassed0013ni.jpg)

http://img379.imageshack.us/img379/1884/310sglassed0026xl.th.jpg (http://img379.imageshack.us/my.php?image=310sglassed0026xl.jpg)

joeldirt
09-04-2005, 08:06 PM
http://img198.imageshack.us/img198/5165/310sglassed1sy.th.jpg


thank you. I am still new to this computer stuff.

Moe Lester
09-04-2005, 08:09 PM
nice :) lookin real good

joeldirt
09-04-2005, 08:16 PM
nice :) lookin real good


thanks moe.

here is the next in line. one of my nitwhit friends was like "Whoa dude" and grabed the lower left corner and stretched the fleece. I'll have to cut a slit arrount the corner and re-stretch it and restaple it. Oh well. Ikind of like this one. Should come out good. Not sure how I should finish it yet.

http://img363.imageshack.us/img363/2328/310sglassed0091kx.th.jpg (http://img363.imageshack.us/my.php?image=310sglassed0091kx.jpg)

http://img363.imageshack.us/img363/1386/310sglassed0108aw.th.jpg (http://img363.imageshack.us/my.php?image=310sglassed0108aw.jpg)

ruckus
09-04-2005, 08:21 PM
thanks moe.

here is the next in line. one of my nitwhit friends was like "Whoa dude" and grabed the lower left corner and stretched the fleece. I'll have to cut a slit arrount the corner and re-stretch it and restaple it. Oh well. Ikind of like this one. Should come out good. Not sure how I should finish it yet.

http://img363.imageshack.us/img363/2328/310sglassed0091kx.th.jpg (http://img363.imageshack.us/my.php?image=310sglassed0091kx.jpg)

http://img363.imageshack.us/img363/1386/310sglassed0108aw.th.jpg (http://img363.imageshack.us/my.php?image=310sglassed0108aw.jpg)

nice that gonna be an aeroport in the center or a logo?

TrlcKed_OuT
09-04-2005, 08:33 PM
very impressive stretching job...i did similar to that but i had some wrinkles...ne good sites have tips for round and curvy stretching tips....

joeldirt
09-04-2005, 08:44 PM
nice that gonna be an aeroport in the center or a logo?

that is a ring for a four inch port. the box right now is a tad over 3 cubes. I supose I could use it for a logo. I bet it would look real nice for a cadilac reath/ shield centered.

the stretching is made real easy when you take the bottom and back piece to your router table and run an 1/8th in rabet joint allong it. you then stretch the fleece over that and run yoru staple gun all along that groove giving you a precise line of staples. I basically run my staples with 1/16th gap or less between and constantly pull the material all along the way. Making sure the curves are equal on each side. You can mess it up if you pull one side harder then the other. An upholstry stapler like mine works best. It is faster and a whole hell of alot easier with better results then just a spring loaded hand stapler. The framing, and stretching and laying up layers of fiberglass is the easy part. Getting an optimum finish is the hardest part....

for instance.... my very first fiberglass project. Please ignore the booty *** sub and amp combo. It is my very first ever and I keep it arround as a joke.

http://img397.imageshack.us/img397/1922/310sglassed0059hk.th.jpg (http://img397.imageshack.us/my.php?image=310sglassed0059hk.jpg)

http://img397.imageshack.us/img397/9331/310sglassed0079op.th.jpg (http://img397.imageshack.us/my.php?image=310sglassed0079op.jpg)

http://img397.imageshack.us/img397/1930/310sglassed0082xf.th.jpg (http://img397.imageshack.us/my.php?image=310sglassed0082xf.jpg)

joeldirt
09-04-2005, 08:52 PM
http://img217.imageshack.us/img217/8730/project11nk.th.png (http://img217.imageshack.us/my.php?image=project11nk.png)

PowerNaudio
09-04-2005, 10:12 PM
very nice looking projects!, what kind of fleece are you using? b/c it looks so nice and clean the way its stretching on the different angles.

joeldirt
09-04-2005, 10:42 PM
very nice looking projects!, what kind of fleece are you using? b/c it looks so nice and clean the way its stretching on the different angles.

thanks, I use fleece from my local fabric mart. its like 4 or 5 bucks a yard. I usually just buy a roll at a time I think it comes in 5 yd rolls. The upholstry stapler works hella nice too.


http://img65.imageshack.us/img65/5449/sglassed0126am.th.jpg (http://img65.imageshack.us/my.php?image=sglassed0126am.jpg)

http://img65.imageshack.us/img65/6644/sglassed0156nc.th.jpg (http://img65.imageshack.us/my.php?image=sglassed0156nc.jpg)

http://img65.imageshack.us/img65/556/sglassed0134iq.th.jpg (http://img65.imageshack.us/my.php?image=sglassed0134iq.jpg)

http://img65.imageshack.us/img65/8774/sglassed0149hf.th.jpg (http://img65.imageshack.us/my.php?image=sglassed0149hf.jpg)

PowerNaudio
09-04-2005, 11:01 PM
man, it looks like you have mastered the art of fleece stretching. lol
again nice work, do you have a website showing off your work by any chance?

joeldirt
09-04-2005, 11:11 PM
man, it looks like you have mastered the art of fleece stretching. lol
again nice work, do you have a website showing off your work by any chance?


LOL, one thing I am yet to master is computers. I ssure don't I just spent the last few hours trying to figure out how to host pictures and make a signature. lol you know the trick to my fleece stretching is my rabet groove allong the back edge. I'll show yopu what I mean....

http://img143.imageshack.us/img143/7663/sglassed0216xj.th.jpg (http://img143.imageshack.us/my.php?image=sglassed0216xj.jpg)

http://img143.imageshack.us/img143/7227/sglassed0189oz.th.jpg (http://img143.imageshack.us/my.php?image=sglassed0189oz.jpg)

PowerNaudio
09-04-2005, 11:23 PM
http://img143.imageshack.us/img143/7227/sglassed0189oz.th.jpg
yep, that is clean, i thought about doing some thing like that, but the extra step, got to me lol. but by the looks of it, its worth it, im going to try that on my next project.

joeldirt
09-04-2005, 11:41 PM
this part is one of the most pain in the butt parts. the sanding..... the amount and duration of sanding, and how much attention to detail is by far the most influencing factor in determining the fate of the finished product of a fiberglass box. Well, one of the biggest. currently it is 6:08 pm same day started

http://img300.imageshack.us/img300/144/310sglassed0225fi.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0225fi.jpg)

http://img300.imageshack.us/img300/6614/310sglassed0231mo.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0231mo.jpg)

http://img300.imageshack.us/img300/6980/310sglassed0243hm.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0243hm.jpg)

http://img300.imageshack.us/img300/4418/310sglassed0256cq.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0256cq.jpg)

http://img300.imageshack.us/img300/9265/310sglassed0268jj.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0268jj.jpg)


http://img300.imageshack.us/img300/66/310sglassed0191yp.th.jpg (http://img300.imageshack.us/my.php?image=310sglassed0191yp.jpg)

joeldirt
09-05-2005, 03:33 AM
day one..... 10 hours.
up next....

I plan to cover the entire face in a finishing resin colored black in three coats, scuff sanding between each coat. once totaly cured I will then comense to more sanding. once perfectly smoothed out, I will go from 60 grit to 120, to 220, then begin to wet sand with 400, then 800, to 1000, finishing with 1500... I will then use pollishing compound and buff it to a deep glossy shine.

after the face is complete, I will carpet the box I built today while waiting for the resin to cure. I still have a couple steps with the box before I carpet it however, including the internal bracing, and holes cut for the ports. I will be using four three inch ports.

looking forward to the finished project... Because I am doing a first... I will take a mold of the face I just made... After the mold is made I can make exact replica's of the face, one after another after another.

joeldirt
09-05-2005, 06:01 PM
late start. it is now noon. Eh.... Fick. Oh well. I scratched the resin idea and decided to go with the traditional paint. Once I start making the molds, I'll use the resin inside the mold before I lay up the reinforcing mat and cloth. Be back later with more pics......

TypeRBass
09-06-2005, 04:55 AM
wow you do good work. awesome stuff.

joeldirt
09-06-2005, 06:24 AM
wow you do good work. awesome stuff.

thank you. Can't wait to get out of the USMC so that I can begin to do this stuff on more then just weekends. I didnt get what I wanted done at all I spent all day cleaning the garage because it was far too impossible to work out of. (this is imaculate compared to what it was before.) here is what little bit I got done on the box(which wasnt much. I added some tint in my body filler to help identify blemishes for when I sanded it away. Now it looks like a cow. oh well, maybe tomorow after work I'll prime it and get to the fine sanding to aply the paint. here are some pics of the face as is... and then the finished product of the garage. lol it was a huge job. Me and my buddy have an acumulation of quite a bit of stuff.

http://img393.imageshack.us/img393/1369/310sglassed0380aq.th.jpg (http://img393.imageshack.us/my.php?image=310sglassed0380aq.jpg)

http://img390.imageshack.us/img390/8766/310sglassed0464gh.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0464gh.jpg)

http://img390.imageshack.us/img390/4043/310sglassed0350cs.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0350cs.jpg)


http://img390.imageshack.us/img390/5665/310sglassed0325cq.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0325cq.jpg)

http://img390.imageshack.us/img390/8423/310sglassed0331yj.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0331yj.jpg)


http://img390.imageshack.us/img390/5089/310sglassed0371dg.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0371dg.jpg)



http://img390.imageshack.us/img390/5997/310sglassed0411sz.th.jpg (http://img390.imageshack.us/my.php?image=310sglassed0411sz.jpg)

if I can suggest a tool to anyone. its the kreg pocket hole jig... (the blue jig with the drill bit in it and the clamp that the sand paper is on.

http://img368.imageshack.us/img368/9412/310sglassed0300xv.th.jpg (http://img368.imageshack.us/my.php?image=310sglassed0300xv.jpg)

it does this:

http://img368.imageshack.us/img368/9066/310sglassed0422dk.th.jpg (http://img368.imageshack.us/my.php?image=310sglassed0422dk.jpg)

http://img396.imageshack.us/img396/6351/310sglassed0443df.th.jpg (http://img396.imageshack.us/my.php?image=310sglassed0443df.jpg)


which is so much easier and cleaner when assembling the box. all done from the inside so no filling in screw holes with putty or bondo. The screws are square drive which are ten times easier to drive then philips head screws. its just all arround awsome and has so many uses. research the kreg pocket hole system if you are interested. the web site has all kinds of info on it. It RockS!

joeldirt
09-06-2005, 04:17 PM
woke up this morning to prime it.

http://img238.imageshack.us/img238/7082/310sglassed0507fz.th.jpg (http://img238.imageshack.us/my.php?image=310sglassed0507fz.jpg)

http://img238.imageshack.us/img238/5290/310sglassed0499px.th.jpg (http://img238.imageshack.us/my.php?image=310sglassed0499px.jpg)

http://img238.imageshack.us/img238/5007/310sglassed0487ow.th.jpg (http://img238.imageshack.us/my.php?image=310sglassed0487ow.jpg)

ruckus
09-06-2005, 04:26 PM
LOL, one thing I am yet to master is computers. I ssure don't I just spent the last few hours trying to figure out how to host pictures and make a signature. lol you know the trick to my fleece stretching is my rabet groove allong the back edge.
Yeah it says that in the glassman videos I have :D

80INCHES
09-06-2005, 04:40 PM
damm thats good work...i wish i knew how to fiberglass ..i want to learn.......if i knoew how i would be making an easy 500 a week just doing one car a week

80

pwnt by pat
09-06-2005, 04:49 PM
What did you use to fill in here?
http://img300.imageshack.us/img300/66/310sglassed0191yp.th.jpg

joeldirt
09-06-2005, 05:21 PM
What did you use to fill in here?
http://img300.imageshack.us/img300/66/310sglassed0191yp.th.jpg


I used the secret sauce in my laminate. After the shape was formed with the fleece and the fleece was completely saturated and cured, I then began to reinforce from the inside. I gave four layers of chop mat. Then I poured in my 3:1 ratio body filler to polyester resin ("secret sauce"when cured hard as a rock!) then I layed on top of that four layers of my fiberglass cloth. Over all the wall is about 3/8 inch thick.

joeldirt
09-06-2005, 05:59 PM
the face will mount to the front just as the back mounts to the back. I havent put in the flanges that the front and back will be seated on to give the permanent mount and air tight fit yet. I will do that nex. I came in for a water break. here it is as of the moment.

http://img283.imageshack.us/img283/908/310sglassed0514is.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0514is.jpg)

http://img283.imageshack.us/img283/5896/310sglassed0526og.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0526og.jpg)

http://img283.imageshack.us/img283/5302/310sglassed0532md.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0532md.jpg)

http://img283.imageshack.us/img283/6828/310sglassed0542zt.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0542zt.jpg)

http://img283.imageshack.us/img283/5707/310sglassed0560zh.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0560zh.jpg)

http://img283.imageshack.us/img283/9467/310sglassed0573us.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0573us.jpg)

http://img283.imageshack.us/img283/9162/310sglassed0583zw.th.jpg (http://img283.imageshack.us/my.php?image=310sglassed0583zw.jpg)


I know you are going to ask how I am going to make the holes for the terminal cups and the ports... If you havent noticed already I have a pretty unique way of doing things. I'll show you how I do it when I get there.

joeldirt
09-06-2005, 06:24 PM
http://img45.imageshack.us/img45/8469/310sglassed0593ob.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0593ob.jpg)

http://img45.imageshack.us/img45/5108/310sglassed0609pa.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0609pa.jpg)

http://img45.imageshack.us/img45/1179/310sglassed0611zp.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0611zp.jpg)

joeldirt
09-06-2005, 06:43 PM
http://img45.imageshack.us/img45/8991/310sglassed0628ls.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0628ls.jpg)

http://img45.imageshack.us/img45/9914/310sglassed0639hr.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0639hr.jpg)

joeldirt
09-06-2005, 07:35 PM
http://img45.imageshack.us/img45/7530/310sglassed0641ke.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0641ke.jpg)

http://img45.imageshack.us/img45/8675/310sglassed0656ug.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0656ug.jpg)

http://img45.imageshack.us/img45/3008/310sglassed0669mr.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0669mr.jpg)

http://img45.imageshack.us/img45/5327/310sglassed0672hj.th.jpg (http://img45.imageshack.us/my.php?image=310sglassed0672hj.jpg)

joeldirt
09-06-2005, 07:56 PM
well that is that for now. I have to go to work (night crew) so next I will be adding the internal braces, and ports.. Then sanding and painting the face.

once the face is perfectly perfect, I will then take the mold of it so that I can make replicas of it when ever I want. I plan to make a few sick *** bandpass enclosures with these. Hope it all works out well. Over and out for now.

joeldirt
09-06-2005, 11:29 PM
what ten's would you guys suggest to put into this enclosure? The total volume after dispacements will be aprox 4.5 tuned to 35 hz. I want some that are very good looking, yet don't cost more then $200.00 a piece. I also would be willing to trade a custom fiberglass box for three decent tens if anyone can get good deals... I was going to put some MTX 7500's in there. I would like to put in some digital designs or some RE subs. The hole cut out is 9.25 now looking for suggestions....

I have also changed my design from four 3in ports to two 4in ports

theCybe
09-07-2005, 09:52 AM
Beautiful work, man. Very nice.

Insomniac119
09-07-2005, 05:34 PM
Awsome work and original. Freaken sweet

joeldirt
09-10-2005, 08:26 PM
here is the carbon fiber so far. I was thinking about getting some immortal ten's to stuff in there since they have **** baskets and carbon fiber cones to match. ( I would put the two outboard subs with cones facing out, and the center with the basket facing out wired in phase since I don't think all three would fit in there together. the baskets on the ten inch immortals arre flippin huge)

http://img366.imageshack.us/img366/3821/310sglassed0684ow.th.jpg (http://img366.imageshack.us/my.php?image=310sglassed0684ow.jpg)

http://img366.imageshack.us/img366/9053/310sglassed0696wv.th.jpg (http://img366.imageshack.us/my.php?image=310sglassed0696wv.jpg)

http://img366.imageshack.us/img366/2567/310sglassed0706jh.th.jpg (http://img366.imageshack.us/my.php?image=310sglassed0706jh.jpg)

http://img366.imageshack.us/img366/329/310sglassed0710od.th.jpg (http://img366.imageshack.us/my.php?image=310sglassed0710od.jpg)

http://img366.imageshack.us/img366/9869/310sglassed0726wb.th.jpg (http://img366.imageshack.us/my.php?image=310sglassed0726wb.jpg)

Mr. Opportunist
09-10-2005, 08:39 PM
cf is girthy ;)

PowerNaudio
09-10-2005, 08:48 PM
that's not bad at all, give it a few more coats of the clear resin, sand and polish and it should look even better.
again you did a very nice job.

joeldirt
09-10-2005, 09:13 PM
that's not bad at all, give it a few more coats of the clear resin, sand and polish and it should look even better.
again you did a very nice job.

thanks,
yeah I plan on sanding it down where it overlaps with some 200 grit, then give it two more coats of resin, and use a liquid posllishing compound and buff the shiat out of it. I am confident it will be a good result. I was kind of nervous about taking on the carbon fiber, but I am a risk taker. Went into it nervously and was kind of up tite the entire time working with it, especcially when I got reoccuring airbubbles ( I finaly was able to work out) and wrinkles ( I cut and overlapped) I even got a bug in the resin I had to remove. Stressful endeavers. Where experience comes from I guess.

joeldirt
09-10-2005, 09:59 PM
did a test fit to see a general idea of how it will look. (I still also have to add the ports)

http://img376.imageshack.us/img376/6321/qskustomsjdaudiobox0806oe.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0806oe.jpg)

http://img376.imageshack.us/img376/6435/qskustomsjdaudiobox0827yy.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0827yy.jpg)

http://img376.imageshack.us/img376/1387/qskustomsjdaudiobox0837yp.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0837yp.jpg)

http://img376.imageshack.us/img376/7076/qskustomsjdaudiobox0858or.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0858or.jpg)

PowerNaudio
09-10-2005, 10:08 PM
thanks,
I was kind of nervous about taking on the carbon fiber, but I am a risk taker. Went into it nervously and was kind of up tite the entire time working with it,

yep i know how you feel, although i haven't work with carbon fiber before, fiber glass you can hide, CF you want it to get looked at, so the finish has got to be nice.

your CF layers is looking pretty decent, just some spots that need some work, im sure youll manage to fix them, cant wait to see the finished results.

slicks5150
09-10-2005, 10:42 PM
killer work. I cant wait to try my hand at fiberglassing. thnx for all the tips bro . I love the way you drop the screws in. I need one of those bits. excelent work!

joeldirt
09-10-2005, 10:59 PM
killer work. I cant wait to try my hand at fiberglassing. thnx for all the tips bro . I love the way you drop the screws in. I need one of those bits. excelent work!

wow, your work is riteous. I bet our work could compliment eachothers nicely. I would really like to eventually learn ow to air brush like that. The kreg jig is at

http://www.gosale.com/show_product.php/4361947-145792/-kreg-k2000pp-propack-pocket-hole-jig

joeldirt
09-10-2005, 11:33 PM
I just scared teh Shiat out of me! Sanded for a split second and thought I ruined teh piece! ! ! ! I couldnt see the caron fiber any more. (the weve) So I quickly thought of a solution... I sprayed a bit of clear coat over the spot I sanded and low and behold the beutiful carbon fiber was still there. So I began to sand confidently. I just will have to go over the whole box lightly with an extremely fine grit sandpaper. Then I will add a couple coats of resin on top of it to get a perfectly smooth een surface. For a little gloss, I may add a coat of high gloss laquer. I think it will turn our nice after all. Wish me luck! ! !

http://img149.imageshack.us/img149/263/qskustomsjdaudiobox0876po.th.jpg (http://img149.imageshack.us/my.php?image=qskustomsjdaudiobox0876po.jpg)

http://img149.imageshack.us/img149/3074/qskustomsjdaudiobox0881fl.th.jpg (http://img149.imageshack.us/my.php?image=qskustomsjdaudiobox0881fl.jpg)

http://img378.imageshack.us/img378/5443/qskustomsjdaudiobox0890ye.th.jpg (http://img378.imageshack.us/my.php?image=qskustomsjdaudiobox0890ye.jpg)

joeldirt
09-11-2005, 12:38 AM
Building up with resin. Will do this one more time tomorow, before I give it the finish sanding. I'll go with the wet sanding up to 1500 then give it the high gloss laquer and pollishing compound. heres what it loos like at the moment.

http://img386.imageshack.us/img386/2974/qskustomsjdaudiobox0907zf.th.jpg (http://img386.imageshack.us/my.php?image=qskustomsjdaudiobox0907zf.jpg)

http://img386.imageshack.us/img386/274/qskustomsjdaudiobox0925zr.th.jpg (http://img386.imageshack.us/my.php?image=qskustomsjdaudiobox0925zr.jpg)

joeldirt
09-11-2005, 02:42 AM
Sanded, laid first coat of finishing resin. Going to lay one more, then will sand perfectly smooth and clear coat.

http://img376.imageshack.us/img376/3893/qskustomsjdaudiobox0997iv.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0997iv.jpg)

http://img376.imageshack.us/img376/3886/qskustomsjdaudiobox0986qi.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0986qi.jpg)

http://img376.imageshack.us/img376/6118/qskustomsjdaudiobox0943ri.th.jpg (http://img376.imageshack.us/my.php?image=qskustomsjdaudiobox0943ri.jpg)

Mark_ab
09-11-2005, 03:14 AM
Very nice work, I like the guts you have to work with CF on those contours.

joeldirt
09-11-2005, 03:28 AM
Very nice work, I like the guts you have to work with CF on those contours.


lol, I wouldnt call it guts, I would call it more ignorance. I hadnt realized how difficult it was going to be with the shape I was trying to do. I guess it turned out okay so far, but it is not perfect. I am going to try again with a less shapely piece. maybe I will have a production mold made specifically for carbon fiber. I am infact just starting out with this stuff. Thanks for the compliment though.

PowerNaudio
09-11-2005, 07:01 AM
[QUOTE=joeldirt]I just scared teh Shiat out of me! Sanded for a split second and thought I ruined teh piece! ! ! ! I couldnt see the caron fiber any more. (the weve)

http://img149.imageshack.us/img149/263/qskustomsjdaudiobox0876po.th.jpg (http://img149.imageshack.us/my.php?image=qskustomsjdaudiobox0876po.jpg)

i was afraid that would happen, that's why i said " a few more layers of resin, then sand, then polish." lol. i read about finishing FG and CF a while back.
remember you only want to sand the resin and not touch the CF at all, the interlacing strands of CF is what gives it the look youre looking for, if you touch the CF with sand paper, you might damage it.

but i guess you figured out a way to fix that,
i love the CF look.
thumbs up

edit: a little of the subject but i have to ask.
do you have any tips on how to work with CF? same as FG? since you have first hand experience and youre good at it i figured id asked. lol

joeldirt
09-11-2005, 07:51 AM
yeah. I only light sanded it. If I were to sand through the fiber, I would have ruined it. The whole thing was a touchy trial. I am glad it is still going well. I laid one heavy coat of epoxy resin. I am going to sand that just to get the high spots out, then see how it is at that point. if it is good to go, I'll shoot it with the clear coat, if I think another coat of resin, I'll do that. I will need another run or two until I get good enough to confidently fabricate to sell at normal price. I'm thinking I would let this one go for $300.00. Think thats reasonable? I still have to *** the internal bracing and the ports. This thing took alot of work so far. They usually don't require this much time and effort. where did you get that piece of literature btw? about the carbon fiber?

PowerNaudio
09-11-2005, 07:56 AM
experimental projects always take longer. lol. 300 bucks thats not bad at all, im should sell quick.
where did you buy the CF?

joeldirt
09-11-2005, 07:59 AM
experimental projects always take longer. lol. 300 bucks thats not bad at all, im should sell quick.
where did you buy the CF?

bought it off ebay. sprt cycles. I also paid for a carbon fiber tutorial to go with it that wasnt much worth it. Oh well here is what they sent me for five bucks. BTW you familiar with Athens TX? my best friend is from there. He said you are right down the road.


1
Carbon Fiber Fabrication
Carbon fiber and composite materials are being used much more in today’s marketplace
from high performance parts and accessories on racecars, boats, planes, models, etc. With
its strength-to-weight ratio there are few other materials readily available that can be used
in such a way as to provide strength as well as being very lightweight. Along with the
weight saving you will have with the pieces you make it will look good too. To make any
structural pieces it would be very hard to do without expensive equipment such as an
autoclave, large die cut molds, etc, etc. This brief “how to” will describe how to fabricate
some small flat pieces and you can go from there. After working with the materials you
will find it much easier than you might have thought.
Here is a brief list of materials that will make the fabrication of your parts
easier, most can be found around the house or local hardware store.
• Flat work surface
• Plastic sheet slightly larger than desired part
• Mold (in this case a piece of glass)
• Mold release (car wax)
• Scissors (for Kevlar fabrics scissors will dull very quickly, Kevlar
shears are recommended)
• Masking tape, ¾” is ok
• Squeegee, plastic or rubber
• Rubber gloves
• Cheap disposable paint brush 1” to 2”
Steps you will be taking:
• Prepare the mold
• Cut the carbon fabric
• Mix the epoxy resin & hardener
• Wet out fabric with epoxy
• Apply wet fabric to mold
• Take out or off of mold
• Finish surface if needed
Preparing the Mold
To prepare the “mold” (which in this case we will use a piece of glass) you can
use a regular car wax. You can buy a mold release but regular car wax will work just as
well and is cheaper. First you will need to clean the surface of the glass. Then apply at
least 4-5 coats of wax giving each coat time to dry and then buff out. Allow 15 minutes
between each coat of wax. Once the wax is done and you have a super smooth and shiny
surface you “mold” will be ready. If your mold is not waxed properly, it will be difficult
to remove piece from the mold. Remember, whatever your mold surface looks like, you
finished piece of carbon will look exactly the same, glossy mold = glossy carbon piece,
dull mold = dull carbon piece.

2
Cut the Carbon Fabric
Cut the carbon fabric slightly larger than the piece you are making giving yourself
approximately 2” all the way around. It might help to outline where you are going to cut
the fabric with some masking tape; this will keep the edges from fraying when you cut it.
Just don’t put the tape on the fabric where it will be in the area you want for the finished
part, the tape will be impossible to get off.
Mix the epoxy resin & hardener
To mix the epoxy resin and the hardener it is a 3 to 1 ratio. Three parts resin to
one part hardener. You can use a plastic container to mix the resin and hardener
thoroughly so that it is an even consistency. In this kit there is enough resin and hardener
to use for more than a yard of fabric. You can therefore mix part of the resin and hardener
in this kit and save the rest for touch ups, which will be described later. This epoxy will
give you a pot life (working time when resin is concentrated in container) of
approximately 20-25 minutes with a room temperature of 77 degrees. The working time
once the resin is spread over the fabric will be at least one (1) hour.
Wet out fabric with the Epoxy
Ideally you would want an epoxy to fabric ratio of 1 to 1 but that is very hard to
accomplish. Don’t worry if you use more epoxy than fabric. If you have a piece of plastic
to lay the carbon fabric on to apply the epoxy that works best. Tape the plastic down on
the edges to your work surface so that it doesn’t move around on you. With the fabric on
the plastic pour the epoxy over the fabric and with a brush (just watch it doesn’t shed) or
a small squeegee, rubber or plastic, spread the epoxy over the fabric until it is completely
saturated moving from the center out. Once this is done carefully turn over the fabric (this
is difficult on larger pieces, you might want a second person) and wet out the other side.
After saturating both sides you can gently squeegee any excess resin off of the fabric. If
you pull or stretch the fabric one way or another, just try and work it back to normal with
the squeegee (this is usually not a problem).
Apply Wet Fabric to the “Mold”
With the saturated piece of carbon fiber, carefully pick it up off of the plastic and
place it onto the “mold” where you want it. It can be laid down and picked up several
times but the more you try and move it the more chances you take of distorting the weave
pattern. Once the carbon is on the mold you can gently squeegee it again to conform the
fabric to the mold and to remove more excess resin (remember you are trying to get a
ratio as close to 1 to 1 as possible). Once the fabric is set onto the mold you can let dry.
Drying time will vary with temperature but usually after 12 hours it will be dry and
hardened enough to use. If possible let dry in a heated area around 75-80 degrees.
3
Take out or off of “Mold”
Once the piece is dry you can use a razor blade or flat putty knife to left up the
edges gently. Once you have lifted an edge you can work the piece off the mold. If the
piece is very hard to get of the mold you can use some thin wooden or plastic wedges to
separate the part from the mold. If this is difficult your mold was not waxed enough.
With the piece separated from the mold you can trim it with scissors if only one layer
thick (for Kevlar hybrids Kevlar shears or saw may be needed), otherwise use a saw or
dremel to cut and trim.
Finish Surface if Needed
If you have any imperfections in the surface of your piece such as pinholes, air
pockets, etc, you may want to try and clean these up. First scuff the piece with some
sandpaper, 220 grit will work. Then clean the piece off thoroughly using air or acetone
(available at most hardware stores). If using the acetone dampen cloth and wipe surface
of carbon part. After part is cleaned you can mix more epoxy resin and recoat or touch-up
the surface with a brush. After this resin has dried you will need to sand and buff to get
glossy surface.
After reading this brief “how to” and working with the materials you will be able
to start out with easy pieces and possibly work you way to making more complex shapes.
It is imperative that all customers understand and recognize that they are solely responsible for their own
skill and judgment when selecting and working with this product. Because Sport Cycle & Salvage, Inc
cannot control how this product is used, it makes no warranties, expressed or implied, including no
warranties of merchantability and fitness for purpose intended. Sport Cycle will not be liable for damages
resulting from use of this product whether incidental or consequential. For Material Safety Data Sheet
contact Sport Cycle & Salvage, Inc.
Caution!
Curing of epoxy generates heat. When contained in a large mass epoxy has a short pot life and
can get hot enough to melt a plastic container or burn skin.
IRRITANT. May cause skin irritation or allergic reaction. Avoid skin contact. Avoid inhalation
of vapors, and work in well-ventilated area. Do not swallow. Wear liquid proof gloves when
handling.
First Aid
SKIN CONTACT: Immediately wipe off resin and clean with waterless cleaner, then wash hands
with soap and water.
INHALATION: Move to fresh air if respiratory irritation occurs.
EYE CONTACT: Immediately flush with water for several minutes and call doctor immediately
if irritation persists.
INGESTION: Seek immediate medical attention if appreciable amounts are ingested.

subboxmaker
09-11-2005, 12:12 PM
hey that box looks great. Could you get a link to what you exactly bought off ebay. I can only find carbon fiber sheets with adhesive backing and im guessing thats not what i would use. Thanks

ruckus
09-11-2005, 12:28 PM
hey that box looks great. Could you get a link to what you exactly bought off ebay. I can only find carbon fiber sheets with adhesive backing and im guessing thats not what i would use. Thanks
carbon fiber cloth

http://search.ebay.com/carbon-fiber-cloth_W0QQfromZR8QQfsooZ1QQfsopZ1QQssPageNameZWLRS

joeldirt
09-11-2005, 07:53 PM
carbon fiber cloth

http://search.ebay.com/carbon-fiber-cloth_W0QQfromZR8QQfsooZ1QQfsopZ1QQssPageNameZWLRS

yes. I went with sport cycle, and they are great with communication. awsome service.

joeldirt
09-14-2005, 01:34 AM
still havent had a chance to work on this since last weekend. Night crew *****! But it is clear of the politic of any work center so it's all good. I have done nothing but work and sleep work and sleep work and sleep past few days. I want to get back to my escapement! As I am very looking forward to the finished product of this piece. I also have to do three tens in a mustang this weekend too. I am going to be worn the F*** out!