| Item | Notes |
|---|
| Process | Vacuum infusion - Estimate setup time of 8 hrs for first layup (everything prior to adding resin)
- Vacuum check must be performed (to ensure vacuum can be held)
- Recommended vacuum pressure should be 27 - 29 inches of mercury (near perfect vacuum).
- Approx 45 min to 1 hr for epoxy to fully absorbe into fibreglass
- For prototype mould, concerns about using envelope bag (if can't pull proper vacuum using reg. vacuum bag)
- Envelope bag could crush and damage mould
|
Layup Materials (Resin, Core, Fibreglass) | Fibreglass - Recommended weave for the fibreglass is 2x2 twill
- Allows for complex curves and sharp ridges to be made from cut off strips from the roll
- Cutting the material at 45° will increase its flexibility by 25-30%
- There should be 4 layers of fibreglass, however other numbers are possible dependent on the shape of the car
Resin
- The recommended available resin is MGS 135 resin, which can be mixed with a hardener to give it a longer pot life
Core - Foam "sandwich" core: DIAB - Divinycell H60
- Flexible and can be cut to size
- Core does not need to be everywhere in the mould (as curves, edges, etc will add stiffness too)
|
| Multiple Panels from Single Mould | Dimensional Wax - Very feasible to make multiple panels using same mould (i.e outer skin of door + side panel)
- Features such as insets and lips for overlapping panels can be added using dimensional wax
- Wax comes in sheets of 1-6mm thick, and can be machined and moulded using heat to fit the specifications
|
| Consumable and Equipment | Resin Tubing - Spiral wrap tubing recommended to be used as the resin feed line
- Offers much greater versatility compared to other methods
Vacuum Gauge - Required to ensure pulling proper vacuum
- Can be a cheap $25 gauge (vs. $300 gauge)
|
| Paint and Windshield | Paint - Using a gel coat is not recommended for fibreglass
- Instead using paint will reduce weight exponentially
- An epoxy primer should be used inside the mould (similar to gelcoat application)
- Will allow for good surface for automotive paint to adhere to
Windshield - For the windshield, check out York Aircraft (make aircraft canopies)
- Possibly consider using pre-made windshields for aircraft, boats, etc. and modifying aerobody
|
| Action Items | - Email Andy to get detailed information on possible contacts for composite materials, equipment, and possible paint sponsor
- Schedule "demo" to possibly construction practice panels at Composite Creation's facilities
|