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Sculpting foam core plugs for carbon fiber parts
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- Опубликовано: 12 янв 2023
- The RUclips channel @rennch. needed a carbon fiber air scoop for a SEMA debut. This video is the results of sculpting a set of scoops to refine a design and get an air scoop on the "Blaspheme build" Porsche 911 resto-mod project. If you need a one off part made of composites this video may be what you are looking for to see a method of sculpting foam to create the "Plug" to get you that part.
Sorry for the low volume/quality of the sound. I have some new equipment and I'm working on the new workflow. What I see/hear in production is different than posted videos; I just need to get them closer to the same, which takes a few cycles. - Jay
Brilliant work as always Jay!
I have not been getting your notifications I have switched them off and put them back on also your volume was very low I had my cans on full still hard to hear you as usual your workmanship was outstanding regards from England.
Great as usual, thx for sharing !
Such a well put together video, cant wait to try that skinning technique on a datsun front clip!
Scoops are looking good .
Thanks for showing your process.
Love your work 👍
Thank you! Cheers!
Watching for a few weeks now. Started at the first video and it will take me a while to get to the newer ones but i hope it will take a long time until i get there. By far my favorit channel on youtube. The videos could be longer. Awesome car awesome videos.
Welcome aboard! Thanks for following the channel!
I'm checking youtube morning and night waiting for your next video, hoping to see a new one soon.
Came to this after studying the process on a fiber and foam supplier's website. I was surprised at the prices of their foam - both polyisocyanurate boards/blocks and expanding polyurethane mixes. They charge $245 for a 4x8 x1" sheet; a six foot block is over $1k!
Immediately my mind went to Home Depot and the extruded foam insulation for this! So to have found this excellent tutorial and see "first hand" it is a practical solution. I'm sure for some applications maybe the expensive stuff would prove useful. (Especially when someone else is paying for the end product - and maybe margins aren't such a concern!)
The very expensive foams have structural qualities that have been documented. If you are building something and need to show (or calculate) the foam into the design then you will need these products. However, if you are just creating a model (plug) then the added expense is just wasted. If you are using the foam as a core, as I have on the Arete Supercar project, just design the structure around the foam to handle the loads required and pretend the foam is just a cavity. If you are using the "big box" store foam in a vacuum or infusion, make sure to test it before committing a whole project. Thanks for watching.
Good video. But audio is very low volume. I think there is some recording problem.
Get you thinking. I have a 911 project that this could be perfect for. Need more air for sure.
Well then, this video is now a tutorial for you - Today is the day!
In your opinion, what flavor of Blue Bunny makes for the best slurry container?
Robota miła dla oka. Pozdrawiam z Polski.
hi, great video! is it xps foam?
I really enjoyed this episode, especially since I've been pondering building something almost the same for my 996 LS swap project. One question, it seemed like you had the foam plug fitting pretty snug in the engine cover, did you take any off around the edges to make space for the thickness of the carbon layers and epoxy topcoat? Or just kind of allow that extra thickness to make sort of a press fit?
Yes, I did take it down slightly with some fine sandpaper, even then, the two layers of carbon add less than 1mm . If Micheal decides to use this part he can take the foam off the back side and reinforce it with a few more layers for an indestructible part.
aaaaay!!!!
Great to see a new video.
Please increase your voice channel volume. I can turn the laptop and YT volume down to 0 if it's too loud but only turn them up so far.
5:54 - re: slurry: does that provide a non-porous layer for the carbon fibre + epoxy layup or something else? (Later you say - something harder to sand).
6:10 - how is that plastic film stuck to the rear panel? I would have thought the heat + weight of expanding foam would move it but it didn't budge - is it static / gravity or magic?
Your craftsmanship in shaping those extruded scoops for the expanded lid was outstanding. I am wondering if it would be quicker or easier to model it in cad and then CNC the foam plug in one piece? That seemed like a lot of work to be told they don't want it 😞
Hopefully we get to see the finished product.
Yes, the slurry seals the foam for a non porous layer. Slurry from microspheres (Q-cells) is softer and easier to sand (softer for dents and damage) the slurry from calcium carbonate is harder and more durable, but of course harder to sand. The plastic film is a product marketed here as Glad press n seal. It has a very light tacky substance applied to it that keeps it in place, but allows it to come off easily. So, basically, until I just gave my secret away - Magic!
@@BuilderCreator ah thank you. Great learnings again, much appreciated.
Is the "slurry" made of bondo type filler mixed with fiberglass resin?
It’s a mix of resin and microspheres
Sound levels are really low - for me.
Great video but volume a bit low.
can you build replica cars
Can, but chose to build original designs instead. Why build a replica when it will never be the real thing?
What is this e-poxy of which you speak? Electronically syphilitic? Epoxy is a contraction of epi- (as in epicure, episode) and oxide, so it's ep-oxy. There's nothing poxy about it. Yes, I know it doesn't matter in the grand scheme of things, but evoking thoughts of syphilis every time you mention it is not pleasant.
still better than donk-eypox....jus sayin'.....
His pronunciation is vastly more pleasant than reading your whinging about your mental associations with syphilis.
...or monkey pox