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BlackFlux
01-29-2004, 10:17 AM
I know this isn't exactly about car audio but I'm getting ready to make a custom PC case. I was thinking about making the entire enclosure/box out of those green floral foam blocks.

http://home.comcast.net/~jragin/Case.gif

Now keep in mind I'm a n00bie. With that said here goes nothing: Which matrial should I use to harden the foam (I was thinking about coating/soak it with fiberglass resin)?

I've done some research but I'm haven't found anything. I should also mention that the final enclosure should weigh just as much as a normal plastic case.

ramos
01-29-2004, 10:50 AM
I'm trying to figure out what your wanting to do. The floral foam isn't going to work so well. I personally just use it to make a mold. By the time you carve away the foam to get the shape you want there will be nothing left structuraly. A carbon fiber case would look pretty cool. :)

BlackFlux
01-29-2004, 11:18 AM
Carving?!?!?!

Ok maybe this will help. The floral foam comes in blocks.

http://home.comcast.net/~jragin/foam.jpg

Slice blocks. Then Glue. You end up with 6 pieces (3 for the top and 3 for the bottom). Glue 3 pieces together to form top. Then glue 3 more pieces to form bottom. Then apply Resin...

I was also thinking of using balsa. You've seen it before its this stuff:

http://home.comcast.net/~jragin/balsa.jpg

Do anyone know if this would work?

ramos
01-29-2004, 12:14 PM
Cut , carve, slice, shape how ever you get the foam in the shape you desire. :) I'm still trying to grasp what your after. The resin will stick to the foam, but the foam with just resin on it is not going to be very sturdy. The balsa wood seems to me a better, and stronger choice. :)

ramos
01-29-2004, 12:22 PM
Are you going to use the floral foam as a mold to lay mat over top of ? Or are you wanting to use the foam itself ? :)

BlackFlux
01-29-2004, 01:04 PM
I was going to use the floral foam as a mold and then I was going to apply fiberglass resin and mat over top of.

Just worried how strong it would be and what would happen when I driller through it. Same goes for the balsa. I was also thinking of building a frame out of the balsa and then pouring some plastic resin down in it.

Something like this:

http://home.comcast.net/~jragin/pour.gif

Any sugesstions?

ramos
01-29-2004, 01:09 PM
Ahhhhhhhhhhhh I understand. I'm having a slow day :D Weight would depend on how many layers and what weight of mat. But you could make a case with fiberglass that would be twice as strong and as light if not lighter than a regular one :)

BlackFlux
01-29-2004, 01:16 PM
I originally thought of using carbon fiber but thought it would be hard to play around with when it comes to cutting , carving, slicing, shaping.

With the foam I would be able to do stuff like this:

http://home.comcast.net/~jragin/resin.jpg

But your probably right about the it being stronger. Do anyone know of any good tutorials for carbon fiber?!?!

ramos
01-29-2004, 02:39 PM
That's pretty cool man :) You can do that with mat, but it's going to take some serious work getting it into all of the crevices. You need a vacuum form machine, that would look sweet made out of plexi :)

TPABlazer
01-29-2004, 08:22 PM
be careful..some foam will melt from resin

MXJMR
01-29-2004, 08:46 PM
I dont know much about styrofoam but i have saw dash's built with i guess just regular styrofoam, then a nice layer of body filler and sand, then paint or what not.

ramos
01-30-2004, 07:14 AM
Polyester resin won't melt the green floral foam, UNLESS you mix it way hot. :)