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SV Carbon Tank project for Zoran

And here, I've painted on a coat of the tank sealer. I like this as an insurance policy.
I keep it away from the flange as that's the part that will bond to the top part of the tank and I want a carbon-to-carbon bond.
This part can be set aside until final assembly. On to the top...

2261366-p1290006.jpg
 
Did you use any sort of gelcoat? My vacuum parts always seem to have pinholes in them, even against something like a polished/waxed metal sheet. And the real clear gelcoats I've seen are too expensive for my taste.

Also, you are just brushing on the pva, right? The only time I brushed it on, it turned out complete crap and I've sprayed ever since. But yours turns out very well.
 
xtasie99 said:
Did you use any sort of gelcoat?
Also, you are just brushing on the pva, right? The only time I brushed it on, it turned out complete crap and I've sprayed ever since. But yours turns out very well.
Click to expand...

No gelcoat and I did get some pin holes with the twill weave. But the finish on my plain weave stuff comes out great. Essentially, the first layer of epoxy is the gel coat. If I want to ensure no pin holes, I just let the first coat of epoxy get uber tacky then lay in the first layer of carbon. That usually results in a perfect surface.
As to the PVA, I just use a blue shop paper towel to wipe it on. I've never had any problems with that approach.
 
tygaboy said:
No gelcoat and I did get some pin holes with the twill weave. But the finish on my plain weave stuff comes out great. Essentially, the first layer of epoxy is the gel coat. If I want to ensure no pin holes, I just let the first coat of epoxy get uber tacky then lay in the first layer of carbon. That usually results in a perfect surface.
As to the PVA, I just use a blue shop paper towel to wipe it on. I've never had any problems with that approach.
Click to expand...

Any movement on the top part yet? Or is that on hold for a bit?
 
drizz said:
Any movement on the top part yet? Or is that on hold for a bit?
Click to expand...

Back to sanding, shaping, etc, on the top. Also taking some time to make my SV fairing parts.
And since I've already posted the process for how I make splitter plates and top molds, I figured no one would find that very interesting. Thought I'd just post the new stuff as I get to it. I was going to throw in 'progress' pics but go light on that until something new was happening.
Let me know if you want the full play by play. - I'd be happy to document the whole thing...
 
How did you "polish? the CF piece, once you pulled out of the mold to the pic where it ia all shiny?
 
Dan071 said:
How did you "polish? the CF piece, once you pulled out of the mold to the pic where it ia all shiny?
Click to expand...
No polishing, no nothing. The purpose of making the plug as perfect as possible is that when the mold is made from the plug, it is a perfect as the plug. And all parts that come off the mold are as smooth and shiny as the mold. That's why I've invested so much in the mold making.
This part was taken out of the mold and all I did was wash off the PVA. That's the beauty of a nice mold.
 
1FastF4i said:
Hey Chris, any updates on the tank?
Click to expand...

Only that I've made very little 'new & exciting' progress. It turns out our donor tank was more damaged than I first realized/noticed. As I started preping it for final shape, it became clear that the right side was way out of shape. I've been bondoing and reshaping for hours and hours. Not too post-worthy, I'm afraid.
The good news is it's about done and ready for the top mold to be made/pulled.

I'll be posting as soon as I start the mold making process (again!).

The BAD news is that carbon fiber is all but unavailable. Boeing and Airbus both have big new planes in production that use a much higher percentage of carbon fiber than previous designs. That, combined with the military demand, has most suppliers only selling to previous customers and us tiny buyers are last on what's becoming a very long list. I was fortunate to get a few yards so I'm covered for this project but sort of hesitant to use it at all!

But for Zoran, hey, I mean he DESERVES a carbon tank, don't you think? ;)
 
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its been a month or so, but fiberglass hawaii in santa cruz had a fair amount
 
(ding) Check any decent glass shop in Santa Cruz.
FGH and FSC is where I get all my CF and Carbon
Kevlar crap on the cheap. Lots of different weaves too.
 
Hi Chris
Thanks for putting all the effort into this. Even though I will probably never attempt this myself it is an interesting read.

I took a basic composites class in college and the bagging process we used is basically identical to what you are doing.

For curing though, we used heating blankets that were laid over the project after it was all bagged. They were small ones and I presume they were made for what we were using them for. I don't know if you have considered this or not but I thought I would mention it.
 
I've not seen the electric blanket approach but it sure makes sense.

Now I just need to find time to get back to this project. Hopefully soon.
 
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