The interior mold continued…

Although Project Hutch has been getting most of my time lately, I was able to get a little work done on OSIDIAS while waiting for some JB Weld to dry… I picked up on the continuation of the molds for the interior assembly. When I last updated, I had the inner mold completed. Now it was a matter of laying out and cutting the exterior. What you see here is another 1′x4′ piece of aluminum sheet.

After cutting…

Time to get this thing bent!

Now, to get one of the inside bends done, I had to switch to my 18″ brake.

With all of the bends done, it was time to see how they fit together. I slipped the outer mold over the inner, and all was well! I’ve got about 2mm between them. That should allow for about 6 layers of carbon fiber.

Since I knew the molds were going to work, it was time to reinforce the inner mold against flexing. All I needed was a piece of 2×4 cut down to 8cm in width. The board was aligned and epoxied in place. Final measurements indicate that I got the perfect alignment I was hoping for. The back is perfectly parallel top and bottom, and I won’t need to make adjustments of any kind.

Up next I’ve got to add a few pieces of angled aluminum for mounting tabs, and I’m ready to wax and lay down the fiber!