Ambitious plan is for it to be contoured to follow deck shape, segmented for flex and made with resin infusion in a silicone mould with a fibreglass jacket. 30mm inner depth for single stack. Not sure on target capacity, and whether I’ll plan it around a high voltage build yet.
Have made the start of a 30mm thick buck (laminated from 3mm thick mdf sheets) and cut the edges to follow the deck outline on router table.
Awaiting new router bit and will then make an offset template to bring in the edges of buck by 20mm for the enclosure flange width. Then lots more steps
Well, winter is here and esk8 is on the back burner for sure. Cold as fuck = no evening building for me. The workshop is unheated and weekends skiiing and family shit is putting the brakes on my progress.
But there has been some small progress on the segmented enclosure project!
Rounded the base of the segment slots with a 9mm round ended bit. Sanded edges to give a small bit of draft on the shape.
Then ordered a special 5mm roundover bit with super small bearing so I could roundover all of the edges and so the bearing would fit in the narrow slots.
Router bit arrived and had finally got some time today, so had a crack at it. Went really well. Made super short work of the job. Would have been a real chafe sanding them, and the router went really well which is awesome
Made a composite base for the wooden buck and trimmed it today.
Will sand to match deck edge profile, maybe offset a couple of mm, glue on the wooden part then paint and sand. I’m estimating a month till then given current progress and speed…
Sick. This didn’t go so well for me but hopefully i got here in time to help… get the hardest silicone you can find. My experiments worked, but the silicone was too soft and the texture of the fibre pushed through no matter what I tried with the vacuum.
The only solution i could think of was to use a harder shore silicone, but after dumping hundreds of dollars and many many hours on the idea, I gave up on it.
I’m fairly certain the stuff that i used was 30A and it was waaaayyyy too soft.
If i were to do it again i’d go as hard as i could find. When i was looking here the hardest seemed to be around 45A, so that 55A one seems ideal.
It’s fucking expensive tho. If i were you, i’d be investigating whether or not you can thicken it somehow while you are working with it, in order to ensure you get an even thickness on all your faces while using the minimum amount of silicone.
Cracked out the spray gun today, bit of a mission but it’s done milestone!
Polyester sanding primer is on, let it cure for a bit and then sand the fucker till it’s smoooooth.
Repainted and started again
180grit pretty much done. The grooves between segments aren’t tho, and I’m not sure if the best approach for them yet. They’re gonna be a pain to do well
