Project: OSIDIAS begins!

[craigbru]

Well, here it goes guys. After more than a year of planning, I've decided to officially to start Project OSIDIAS. Granted, I still have other projects I'm still working on, but I don't want to delay this any longer. I can't promise daily updates, but I have a feeling you all will keep motivated to keep my work as updated as possible.

OSIDIAS will take everything I've learned from my Rogue project, and double it, in both scope and ambition. I've got some pretty unique things I'll be attempting here, and I've got no assurances that everything will work out as I've planned. That doesn't matter though, as I enjoy the challenges of problem solving on the fly. Even though at this point, almost every detail of the case is planned, there are still going to be things I decide to change. However, due to the way the case is designed, there are certain things that must remain set in stone. The overall exterior of the case and the carbon fiber shell for example.

So, where do we begin? Well, for those that may not have been following along up until this point, this (http://www.vimeo.com/8832516) video gives the best project overview. If you've got 20 minutes to spare, this should catch you up to speed.

Now, although this is the first official post of the project, I've only got a few pics to show you. Don't worry, I've got more incoming, but I this should get things started. :D

This case will be the first time I move away from aluminum as my primary construction material. There will still be plenty of it in this case, but I figured it was time for something more exotic. That's where carbon fiber comes in to the picture. Actually, carbon fiber, as well as a carbon fiber/kevlar blend. The carbon fiber will be placed around molds that I'm currently building, and them vacuum bagged. This is a proven technique for manufacturing, but the first time I'll be attempting it. There aren't many computer mods made from CF, let alone molded as in what I'm trying, but that's where the fun part comes in! I've got to give full credit to MKmods for his advice and input regarding working with carbon fiber. With any luck I'll not end up with a very expensive mess on my hands...

I mentioned having to make the molds, and that's where the following pictures pick up. Thanks to the help of my Romaxx CNC machine, I was able to accurately cut out a few pieces of the OSIDIAS core. These pieces will sit in the center, while an aluminum 'clam-shell' sits around it. After the carbon fiber and vacuum bagging, the idea is to push the center core out, and then remove the shell from the inside. This will leave a solid CF case, from which I will make the needed cuts.

Here are the blank pieces of MDF ready for the Romaxx CNC.

http://losias.net/projects/osidias/pictures/p4180312_0.jpg

After the CNC cut...

http://losias.net/projects/osidias/pictures/p4180313_0.jpg

http://losias.net/projects/osidias/pictures/p4180314_0.jpg

And finally, I've got a stack of them.

http://losias.net/projects/osidias/pictures/p4180315_0.jpg

Next up, we've got the core assembly!

[x88x]

Woo! Finally it starts! :D I can't wait to see how that CF bubble-thing goes.

[Langer]

YEE-HA!

Looking forward to this one, very much.

Goodluck

[OvRiDe]

OMG OMG OMG OMG... I have been waiting for this day!!!

Can't wait to see this one unfold!

[Oneslowz28]

This is going to be good! This is now the second thread I have ever subscribed to.

[craigbru]

Woo! Finally it starts! :D I can't wait to see how that CF bubble-thing goes.

Thanks mate! Well, I hope!


YEE-HA!

Looking forward to this one, very much.

Goodluck

Thanks Jesse! You know, you are partially responsible for this thing being made out of CF. :D


OMG OMG OMG OMG... I have been waiting for this day!!!

Can't wait to see this one unfold!

Thanks! I've teased it's start for so long now, it's about time I follow through!


This is going to be good! This is now the second thread I have ever subscribed to.

Wow, thanks! I'm honored to make your sub list!

[SXRguyinMA]

this should be good! +rep and +sub

[craigbru]

this should be good! +rep and +sub

Thanks!

Are you guys ready for another update?

My last post left off with the cut MDF pieces for the core of the case. What I needed now was some simple way to fasten those pieces together, while still providing strength. I went round and round with possibilities until I decided on the following method. It all started with a trio of 22mm holes courtesy of the Romaxx.

http://losias.net/projects/osidias/pictures/p5310350.jpg

Thanks to the CNC's accuracy and repeatability, I ended up with 6 pieces just like this.

http://losias.net/projects/osidias/pictures/p5310351.jpg

With the first piece laying down, I tapped 3 sections of PVC pipe into the holes. The fit was just tight enough that there was no movement once in place, but taps with a hammer could still allow any needed adjustment.

http://losias.net/projects/osidias/pictures/p5310352.jpg

Now finally, here is the assembled core. It's lightweight, yet very strong. The PVC pipe not only serves to hold the structure together, it also has a secondary purpose. Since the carbon fiber will be vacuum bagged, the pipe will allow for pressure equalization between the front and rear of the mold.

http://losias.net/projects/osidias/pictures/p5310353.jpg

With the core done, I'll be moving on to the 2 part aluminum shell that fits around it. Thanks for reading!

[x88x]

Great idea! That flat thingy around the bit on the Romaxx is new..is that a vacuum attachment?

[Kayin]

Excellent work!

I may have to contact you about just what that CNC can do...

[craigbru]

Great idea! That flat thingy around the bit on the Romaxx is new..is that a vacuum attachment?

Good catch! Yes, that is a vacuum boot. It was recently added. It has it's obvious benefits, but sometimes it can be just as much of a pain. It sometimes gets in the way of clamps and hold-downs should I need them.


Excellent work!

I may have to contact you about just what that CNC can do...

Thanks Kayin!

(I'm pretty easy to catch should you want to chat.)

[craigbru]

With the core of the mold done, it's time to get some aluminum wrapped around it. It's a pretty simple concept, but I need perfect execution. The aluminum needs to fit the MDF perfectly, as it ultimately will determine the shape of the carbon fiber on top of it.

I'm starting by using some AC Ryan 1mm sheets that I had lying around. I've had these for quite some time courtesy of the Rogue project's bit-tech Mod of the Month win almost 2 years ago already. I figured it was time to put them to use.

http://losias.net/projects/osidias/pictures/p6010354.jpg

One of the newer pieces of equipment in my shop is this metal brake. I've retired the little 18" unit I had, and moved up in the world. To say that it's a huge improvement, is understating the obvious. So, I marked out the aluminum, and slid it in place for the first bend.

http://losias.net/projects/osidias/pictures/p6010355.jpg

A second bend later, and things are looking good!

http://losias.net/projects/osidias/pictures/p6010356.jpg

An additional 4 bends brought me to this.

http://losias.net/projects/osidias/pictures/p6020357.jpg

A quick test fit, and it was looking pretty good. Well, good enough to move on to the other side. At least for the moment...

http://losias.net/projects/osidias/pictures/p6020358.jpg

I made the second panel, and after evaluating it's fit, I decided to remake the first one. Ultimately I just wasn't happy enough with the way it fit the contours of the MDF core. It couldn't have been more than a single millimeter off in the way that it fit one of the edges, but it was still too much for me. I sometimes tend to set standards for myself that seem unreasonable, but when something is bugging me, I just can't let it go. So, the red panel is gone, and it's been replaced with blue and green...

http://losias.net/projects/osidias/pictures/p6020348.jpg

Since I was pretty happy with the fit of the new panels, I now needed to get them marked and cut to fit. I need perfectly flush mating on the top and bottom joints, and I'll cover that in the next update.

http://losias.net/projects/osidias/pictures/p6020349.jpg

[x88x]

Mmmm, pretty aluminum..ness..

[craigbru]

Lol, it is pretty, but it's about to get covered with something even prettier. :D

[Mach]

Quick get the kids and the dog into the bunker. He's started building skynet. We're all doomed :)

Glad to see this one is underway. Consider me sub'd. :up:

[craigbru]

Quick get the kids and the dog into the bunker. He's started building skynet. We're all doomed :)

Glad to see this one is underway. Consider me sub'd. :up:

Lol, funny. It's also ironic that Terminator 2 is on TBS in the background as I type this... :whistler:

Haha, there's nothing like the smell of a warm Dremel on a beautiful Thursday night... With my last update, I was ready to trim the top of the aluminum shell down to size. A few minutes of cutting and filing left me with a prefect fit. It's absolutely straight with no gaps.

http://losias.net/projects/osidias/pictures/p6030348.jpg

Now it was time to do the same thing on the bottom. I always mark first with either a pencil or fine point Sharpie, and then follow up with tape. When I cut, I get as close to the tape as possible, then finish up with a file. I find that it's easier to follow the edge of the tape, than it is any regular line.

http://losias.net/projects/osidias/pictures/p6030349.jpg

http://losias.net/projects/osidias/pictures/p6030350.jpg

Once again, after cutting...

http://losias.net/projects/osidias/pictures/p6030351.jpg

Okay, so what's next? With the aluminum shell done, I've got to prep for layering on the carbon fiber. Since I'll have multiple layers basically rolled on the mold, I needed an easy way to apply the CF. The following method is what I came up with. I've got a pair of sawhorses and a piece of aluminum channel through the center pipe on the mold. This will allow me to roll the mold in to any position, yet the square planes of the channel means that it won't roll away when I don't want it to.

http://losias.net/projects/osidias/pictures/p6030354.jpg

Now let's take a look at my box of goodies from Aerospace Composites. I've got a vacuum generator, check valve, associated vacuum bags, and peel ply. I'll be using all this to ensure as flawless a finish as possible.

http://losias.net/projects/osidias/pictures/p6030353.jpg

At this point I decided to do a small resin test. I've seen far to many instances where resin doesn't set, and I want to make sure I've got a workable ratio. The last thing I need is a mess on my hands. Up next, the fun part!

http://losias.net/projects/osidias/pictures/p6030352.jpg

[x88x]

8D Giant roll of CF... Shiny! :D

[jiggiwiddit]

Respect @ the amount of planning +sub. looking forward to this :up:

[craigbru]

8D Giant roll of CF... Shiny! :D

It is a little mesmerizing, isn't it? :D


Respect @ the amount of planning +sub. looking forward to this :up:

Thanks man. I couldn't not afford to plan this one well. The material cost makes mistakes... undesirable.

[Waynio]

Wow, this looks ambitious just watched the walk through video & read up to now, action packed super fun happy box it looks like :D, I'm gonna enjoy watching this progress :), keep up the awesomeness Craig :up:. +rep here & on bit-tech :D

[CorrodedZoul]

craig, this is an awesome project, +rep & +sub!!!
Wish you best luck with this!!!!!!

[craigbru]

Wow, this looks ambitious just watched the walk through video & read up to now, action packed super fun happy box it looks like :D, I'm gonna enjoy watching this progress :), keep up the awesomeness Craig :up:. +rep here & on bit-tech :D

Lol, thanks Waynio!


craig, this is an awesome project, +rep & +sub!!!
Wish you best luck with this!!!!!!

Thanks man!

Ready guys?

Well, working with the carbon fiber was an interesting experience. I got completely prepped and ready to go last night, so that I could start wrapping first thing this morning. I'll admit to being a bit nervous. I didn't have any room for error, and with my OCD about having things perfect, the pressure was on.

I woke up this morning, headed to the shop, and cranked up the music. A little Zune Pass with Breaking Benjamin as the starting point, and things were underway! What you'll see here is the mold ready to go, with the carbon fiber strips sitting on a tube right behind it. This would allow me unroll the CF onto the mold with minimal handling.

http://losias.net/projects/osidias/pictures/p6050349.jpg

It was now time to mix up the resin. I was using a marine grade clear epoxy with a 109 medium hardener. This stuff has a pot life of about 30 minutes, so there was no time to do anything but get underway. With the resin mixed I was on the clock. I slipped on my rubber gloves and hit the mold with a layer of resin from a 4" lint-free roller. The first layer of CF was on soon after.

I continued wrapping and rolling, taking extra care not to deform or stretch the CF in any way. I also had to be sure that all the corners had the fiber nestled in them without issues. I thought I was making good time until I went to apply a little more resin, and the roller started to pull up on the CF. Crap! That meant my resin was hardening. Had it really been 30 minutes already? Well, it didn't matter. I couldn't do anymore at this point. I needed to wrap peel ply around it and get it bagged. I still had one layer to go, but there was no way I could get it on without causing serious issues. So, bag it, I did...

http://losias.net/projects/osidias/pictures/p6050350.jpg

I smoothed the bag out a little and left it under vacuum for about 2 hours.

http://losias.net/projects/osidias/pictures/p6050351.jpg

Now, aren't you all excited to see what's next? Yeah, I am too, but I had to head out of town for the rest of the weekend. The next update will likely be late Monday or Tuesday night.

So, overall, the experience wasn't as bad as I thought it might be, but I was cutting it close with the resin cure time. I also know I'll have a few ridges in the resin from the bagging process, but that's really not an issue right now. I can sand and add more resin. In addition, I'll likely go ahead and add the last layer of missing fiber. I'll update early this week guys!

[SXRguyinMA]

nice work! can't wait to see it unwrapped! And good choice on Breaking Benjamin :D If you like them check out Crossfade, those guys are awesome :up:

[x88x]

Nice! Bad luck on the resin though. Will you be able to go back and put on the last layer later?

Also, question about the bagging process. Everywhere I've seen CF done before requires crazy high pressures and thus expensive machinery. Does this process create as strong a composite as that? I'm thinking over some projects I have planned long-term, and if this creates anywhere near the strength of high-pressure setting... :twisted:

[craigbru]

nice work! can't wait to see it unwrapped! And good choice on Breaking Benjamin :D If you like them check out Crossfade, those guys are awesome :up:

Thanks man! I do have some Crossfade in my playlist, along with Evan's Blue, Cold, deftones, Seether, etc. I'll either use the Zune Smart DJ or Pandora, and I've always got a great mix of tunage.


Nice! Bad luck on the resin though. Will you be able to go back and put on the last layer later?

Also, question about the bagging process. Everywhere I've seen CF done before requires crazy high pressures and thus expensive machinery. Does this process create as strong a composite as that? I'm thinking over some projects I have planned long-term, and if this creates anywhere near the strength of high-pressure setting... :twisted:

Yes, it was a little unfortunate, but it's fixable. It just means some sanding and filing is needed. I need to get the surface perfect before the last layer of CF goes on. Even if I couldn't put the last layer on, what I have is cosmetically fine. It's just a resin issue, and that can always be fixed. Things like wrinkles in the CF couldn't be.

I'm not sure high pressures are needed for an application like this. The little test piece I made last week, was crazy stiff, and it was only 5 layers. I'm certain this is much stronger than aluminum, and it won't deform, it will flex and deflect.

[x88x]

It's just called 'carbon fiber bagging', right? I'll look into it some more...it would definitely be worth it if it works.. For context, the application I'm thinking of is for the monocoque or frame of a few different vehicle ideas, ranging from <100lbs to maybe half a ton. (Waiting on me having a garage and more expendable income...like so many other project ideas..)

[craigbru]

It's just called 'carbon fiber bagging', right? I'll look into it some more...it would definitely be worth it if it works.. For context, the application I'm thinking of is for the monocoque or frame of a few different vehicle ideas, ranging from <100lbs to maybe half a ton. (Waiting on me having a garage and more expendable income...like so many other project ideas..)

Yes, bagging or vacuum bagging. Wow, you're application would be a little more heavy duty than mine. I'm not sure what your results would be on such a large scale.

Anyway, I apologize for not updating last night guys. I've been struggling with a pinched nerve in my neck, and subsequent pain in my right arm. It was really bad yesterday, and I didn't even make it down to the shop. I'll be having an MRI done tomorrow, and likely have a surgery in my future. It sucks, but I'll keep plugging away. Despite being in a little pain, I'm gonna show you the CF. What you are looking at is the final layer of fiber needed on the case. I'll have to lightly sand a few small air bubbles, but otherwise it's cosmetically pretty darn good. I'm also going to apply one more layer of resin before I remove the mold. I want to be sure the CF is well protected from damage. It's a whole lot easier to sand and fix resin than have a blemish in the fiber itself...

http://losias.net/projects/osidias/pictures/p6080348.jpg

http://losias.net/projects/osidias/pictures/p6080349.jpg

http://losias.net/projects/osidias/pictures/p6080350.jpg

http://losias.net/projects/osidias/pictures/p6080351.jpg

[x88x]

Mmmm, that is pretty. :D

[silverdemon]

looking very nice! keep up the good stuff!

and let's hope the neck/arm-thing is not too bad...

[craigbru]

Mmmm, that is pretty. :D

Thanks. It did turn out as well as I'd hoped.


looking very nice! keep up the good stuff!

and let's hope the neck/arm-thing is not too bad...

Thanks man.

Yeah, hopefully I can get the pain sorted, because it's a constant distraction.

[Waynio]

Looking sweet :):up: & hope you get well soon bud.

[craigbru]

Thanks Waynio. I hope so too.

I was hoping to get another layer of resin on tonight, but I forgot to shut the air conditioning vent in the shop last night. It was too cool for the resin to cure as it should, but will be ready by tomorrow. Sadly, I've got plans this weekend, so I'll likely not have another big update until early next week.

[craigbru]

With the weekend come and gone, it's time I update all of you on my progress. It's not much, but as always, it's still a step forward. So, how about we get the case out of the mold? I designed the mold so that not only would it be reusable, it would be easy to remove. The first thing I did was to set the case on the workbench, and start tapping the core from one side to the other.

http://losias.net/projects/osidias/pictures/p6140348.jpg

http://losias.net/projects/osidias/pictures/p6140349.jpg

A few more taps...

http://losias.net/projects/osidias/pictures/p6140350.jpg

The core removed.

http://losias.net/projects/osidias/pictures/p6140351.jpg

Now it was a matter of removing the aluminum shell.

http://losias.net/projects/osidias/pictures/p6140352.jpg

It's finally free! The case is completely removed from the mold. You can see a few small voids on the interior, but those are a non-issue at this point. Anything that remains after the exterior holes are cut, will be filled in with resin and leave a smooth surface behind.

http://losias.net/projects/osidias/pictures/p6140353.jpg

http://losias.net/projects/osidias/pictures/p6140354.jpg

Now, I'll add a few comments about the case itself. It's strong! In fact, it's shockingly strong. Sure, everyone knows carbon fiber has excellent strength properties, but until you experience it for yourself, it's a little hard to quantify. This case has almost no flex or deflection. I can press on the center of both sides with about all the strength I can muster, and it just barely moves. It's just that solid. On top of it's strength, it's also incredibly light. Also, I'm saving the rest of the surface work until after all the holes are cut. This thing will be as smooth as glass once completed. All in all, this was the perfect building material for this case, and I can't wait to start making my first cuts in it. Stick around for the fun coming up next!

[rendermandan]

Looks like I won't be the only one with a CF case anymore.

LOL, seriously, excellent job so far! Keep up the good work.

[x88x]

It looks great! Good to hear about the strength, I was worried that this would be a 'too good to be true' scenario with the incredibly cheaper fabbing process.

[craigbru]

Looks like I won't be the only one with a CF case anymore.

LOL, seriously, excellent job so far! Keep up the good work.

Thanks! I watched your project closely, and it gave me quite a bit of inspiration to work with CF myself.


It looks great! Good to hear about the strength, I was worried that this would be a 'too good to be true' scenario with the incredibly cheaper fabbing process.

Not at all, it's truly amazing. You just have a hard tome believing it until you experience it for yourself. So...

Time for another update!

Now that the case is out of the mold, I need to get it cut down to size. I use my trusted tape marking method, and prep the Dremel. That's really the only practical way to cut the case with it's uneven contours.

http://losias.net/projects/osidias/pictures/p6140348-2.jpg

The first cut done. Would you believe that the CF cuts like butter with a reinforced disc? You can't drop the disc in and do a continuous cut without binding, but it you drop in every centimeter or so, it works very well.

http://losias.net/projects/osidias/pictures/p6140349-2.jpg

http://losias.net/projects/osidias/pictures/p6140350-2.jpg

Not only does the fiber cut extremely well, it takes to filing beautifully too. This pic was taken after filing and a quick bout with a fine grit sand paper. After cutting, I could finally get a measurement on the actual cross section of the case. It measures just under 2mm. That's even better than I thought.

http://losias.net/projects/osidias/pictures/p6140351-2.jpg

http://losias.net/projects/osidias/pictures/p6140352-2.jpg

With the first side done, it was time to mark the other side.

http://losias.net/projects/osidias/pictures/p6140353-2.jpg

All done! The case now measures the perfect 40.6cm I needed. Up next, I'll be marking out and cutting all the holes needed in the case. Until then!

http://losias.net/projects/osidias/pictures/p6140354-2.jpg

[x88x]

Nice! I always wondered about how hard it would be to cut CF. Though now that I think about it, it makes sense. I mean, after all, it's basically just fabric and resin.

[SXRguyinMA]

yea but CF will burn through regular steel tools MUCH quicker than, say, regular fiberglass will. I went through. For isntance, I went through 4 drillbits making the cribbage board. Had it been regular fiberglass I aws drilling I probably could have done it with 1, maybe 2 at most. CF is VERY strong. the fibers eat and dull steel VERY quickly. When I was making the backplate for Rockin Case, I went through 5 or 6 side cutter bits cutting that thing out, it was nuts.

[craigbru]

Nice! I always wondered about how hard it would be to cut CF. Though now that I think about it, it makes sense. I mean, after all, it's basically just fabric and resin.

Yes it is. Using a reinforced disc worked well, but CF is very hard on other metal cutting tools. For example, if I run this through my CNC, end mills wouldn't stay sharp for long. Exactly how long I'm not sure, but I'll find out soon enough. :D

[craigbru]

yea but CF will burn through regular steel tools MUCH quicker than, say, regular fiberglass will. I went through. For isntance, I went through 4 drillbits making the cribbage board. Had it been regular fiberglass I aws drilling I probably could have done it with 1, maybe 2 at most. CF is VERY strong. the fibers eat and dull steel VERY quickly. When I was making the backplate for Rockin Case, I went through 5 or 6 side cutter bits cutting that thing out, it was nuts.

Very well said! (You beat me to the reply button.)

[SXRguyinMA]

Very well said! (You beat me to the reply button.)

you're just slow on the draw :D that thing's lookin crazy BTW :banana:

[craigbru]

Thanks man. Lol, it's entirely possible I'm just getting old.

[SXRguyinMA]

yea it could be. I just turned 26 in January so I've got some time lol :D

[rendermandan]

Please tell me you are using a resperator when cutting that CF.
I don't mean the white paper face mask type, I mean a full resperator that is fitted to your face and you have the appropriate filters for type of particle.

here is me wearing one.
http://i65.photobucket.com/albums/h205/rendermandan/Dark%20Carbon/100_6222.jpg

Believe me, I learnd from experience on Dark Carbon.

[Loki]

Wicked job!!! can't wait for another update, +REP on that CF cutting :D

[x88x]

Craig or anyone interested, who doesn't already know, I looked into it, and apparently the different methods of setting CF are tied directly the resin application method used. Either you do basically what was done here, laying out the CF, applying the resin, and curing it at room temperature, or you can use pre-impregnated CF, where the resin has been impregnated into the CF at the factory, and frozen to keep the resin from setting. This then requires an oven or autoclave for curing. The pre-impregnated CF has the benefit of being more consistent, so likely stiffer and stronger, but of course is much more expensive and difficult to make.
http://www.nsxprime.com/FAQ/Miscellaneous/carbonfiber.htm

[Luthien]

The case is looking great. I'll be honest and admit I know nothing about working with carbon fiber, but it appears to take to cutting and filing well.

[craigbru]

yea it could be. I just turned 26 in January so I've got some time lol :D

Lol, I've got 10 years on you.


Please tell me you are using a resperator when cutting that CF.
I don't mean the white paper face mask type, I mean a full resperator that is fitted to your face and you have the appropriate filters for type of particle.

here is me wearing one.
http://i65.photobucket.com/albums/h205/rendermandan/Dark%20Carbon/100_6222.jpg

Believe me, I learnd from experience on Dark Carbon.

I am indeed. It's hot and uncomfortable under the shop lights, but better safe than sorry.


Wicked job!!! can't wait for another update, +REP on that CF cutting :D

Thanks Loki!


Craig or anyone interested, who doesn't already know, I looked into it, and apparently the different methods of setting CF are tied directly the resin application method used. Either you do basically what was done here, laying out the CF, applying the resin, and curing it at room temperature, or you can use pre-impregnated CF, where the resin has been impregnated into the CF at the factory, and frozen to keep the resin from setting. This then requires an oven or autoclave for curing. The pre-impregnated CF has the benefit of being more consistent, so likely stiffer and stronger, but of course is much more expensive and difficult to make.
http://www.nsxprime.com/FAQ/Miscellaneous/carbonfiber.htm

Cool stuff. Thanks for the linkage. I'm sure that stuff has it's uses, but I can't imagine it being used well for us modders.


The case is looking great. I'll be honest and admit I know nothing about working with carbon fiber, but it appears to take to cutting and filing well.

It really does. I was pleasantly surprised.

Well guys, I've got some bad news, my quest for perfection is going to cause a delay in moving in with part of this project... I've decided I'm not happy with a few things. I don't feel the outer edges are 'sharp' enough. I think a side effect of the initial multiple layers of CF and the resin hardening too soon, have left things more rounded than I would like. The only way to fix this is to sand the case down, and add another layer of fiber. I can't just sand down what I have and resin because I'll have to sand through a little CF to get it flat. Obviously that will kill the cosmetics. While most of you think it looks great, it's just something that I've decided will bug me. I can't put countless hours into it, only to wish I had fixed it. So, what now? Well, luckily I still have work to do... I'll go ahead and start on the side panels. I've got to order more fiber, and the side panels will allow me to fill the time until it arrives.

[silverdemon]

Sad to hear there's a short delay, but when you make such a case you'd better make it perfect.
Like you said, you will always look at it and think that it's not good enough (for yourself) if you don't fix it

That being said, I really like this case already!

One other thing The edges you cut of probably contain some sharp edges and maybe splinters. If you cut yourself or have a splinter in your hand or other body part you should really take it out immediately. I heard that carbon splinter will grow INTO your body (whereas metal or wood will grow out) When it reaches you bones and can not grow any further it will start to rot and leave very nasty internal infections...

[Luthien]

One other thing The edges you cut of probably contain some sharp edges and maybe splinters. If you cut yourself or have a splinter in your hand or other body part you should really take it out immediately. I heard that carbon splinter will grow INTO your body (whereas metal or wood will grow out) When it reaches you bones and can not grow any further it will start to rot and leave very nasty internal infections...

Ouch! That's a good thing to know. I haven't worked with the stuff, but if I ever do now I know to be extra careful. Thanks for the info.

[Kayin]

Any CF fabric left over? I have a project in mind, and it needs just a bit of CF fabric... LMK, or let me know where you got yours.

[craigbru]

Sad to hear there's a short delay, but when you make such a case you'd better make it perfect.
Like you said, you will always look at it and think that it's not good enough (for yourself) if you don't fix it

That being said, I really like this case already!

One other thing The edges you cut of probably contain some sharp edges and maybe splinters. If you cut yourself or have a splinter in your hand or other body part you should really take it out immediately. I heard that carbon splinter will grow INTO your body (whereas metal or wood will grow out) When it reaches you bones and can not grow any further it will start to rot and leave very nasty internal infections...

Thanks!

I've only gotten a few minor slivers, and they were removed immediately. Luckily they are black and easy to see.


Any CF fabric left over? I have a project in mind, and it needs just a bit of CF fabric... LMK, or let me know where you got yours.

How much are you looking for? I've got a few small pieces. One is only about a foot square, and I think the other is maybe about 10" x50". If you need more than that, I got mine on ebay from elitemotoring.

[Kayin]

Will PM you. Thanks for the info!

[craigbru]

Although it's not quite as large an update as you all were expecting, I did manage to get a few things done over the weekend. A lot of people have questioned why I wanted to bother sanding down the case and adding another layer of fiber. Well, I've got a few pics that can hopefully show you in more detail why I wasn't happy. At this point, the case is sanded and ready for it's last layer of CF. It's nowhere as pretty as it was before the sanding, but that will be remedied soon. Trust me... :D

http://losias.net/projects/osidias/pictures/p6190351.jpg

Now, here is the best way I can show you the before and after examples of the 'rounded' edges I was speaking of. This should make things pretty clear. This is a before pic, taken of the excess I cut off of one of the ends...

http://losias.net/projects/osidias/pictures/p6190353.jpg

Now take a look at the after. You can see there is no more rounded edge, and I'm much happier.

http://losias.net/projects/osidias/pictures/p6190352.jpg

Okay, now with that out of the way, it's time to move on to the side panels. I'll be working on them until I have more regular CF arrive to finish the case itself. As you are about to see, making the molds for these panels is a whole lot easier than before. Two bends and I was golden. This nice piece of aluminum will be the basis of what is to come.

http://losias.net/projects/osidias/pictures/p6190354.jpg

A few bends later...

http://losias.net/projects/osidias/pictures/p6200355.jpg

Now I've just got to get the CF/Kevlar blend cut to size, and I can get the fiber laid down. Hopefully tomorrow!

http://losias.net/projects/osidias/pictures/p6200356.jpg

[x88x]

Nice. I like the look of that blend.

[craigbru]

Well, I've got a little more work done on the side panels. I'm using the same molding process as the case, but it's nowhere near as complex this time around. Here is the Kevlar/carbon fiber blend laid out and ready for marking... Isn't it pretty?

http://losias.net/projects/osidias/pictures/p6220348.jpg

I've marked out the fiber, and am making my cuts here. This stuff truly sucks to cut. Even with a specialty shears, it has a tendency fray and not cut cleanly. I wouldn't ever attempt this with regular scissors. I would imagine you would slit your wrists in frustration.

http://losias.net/projects/osidias/pictures/p6220350.jpg

Now finally, here are 5 layers of fabric freshly removed from the vacuum bag. I've still got plastic peel ply on it, but that will come off tomorrow. I'm going to sand a little, and add one more layer of Kevlar. The same procedure I used on the rest of the case, should get me pretty good results. The trick will be in finding the perfect piece of fiber for the top layer. The weave on this blend is very sensitive, much more so than with regular carbon fiber. Every little flaw or misalignment seems magnified 10 fold. I'll manage though... or go insane trying!

http://losias.net/projects/osidias/pictures/p6230351.jpg

Tomorrow I'll get the other panel started, and sand this first one. Then I've got to get an end mill or two ordered for the Romaxx CNC. I'll be using it to cut out the side panels. I'll do a few test runs first, since I don't want to screw one of these up. Mistakes would be costly...

[Loki]

Nice... really shiny fabric... Can't talk.. I'm dripping drool XD

[x88x]

That panels looks awesome! Did you make it a bit larger than it'll need to be? I'm just wondering how you're gonna handle the tape on the edges.

[craigbru]

Nice... really shiny fabric... Can't talk.. I'm dripping drool XD

Thanks man!


That panels looks awesome! Did you make it a bit larger than it'll need to be? I'm just wondering how you're gonna handle the tape on the edges.

Thank you. Yes, the panel is bigger than it needs to be on all sides. I'll have to cut it down after the last layer of kevlar is on.

[craigbru]

If it weren't for pictures like the following, I'd take the Kevlar/CF blend, and make it disappear... Yes, it's a royal pain to work with. I knew it would be, but until you are actually working with it and trying to make it do what you want, you have no idea...

http://losias.net/projects/osidias/pictures/p6250349.jpg

http://losias.net/projects/osidias/pictures/p6250348.jpg

http://losias.net/projects/osidias/pictures/p6250350.jpg

It doesn't like to cut cleanly, no matter the process. The Kevlar fibers really have a mind of their own. I've found that I get the best results if I start cutting with a metal carbide cutting wheel. That cuts quickly, but not cleanly. I then followup with a reinforced cutting disk. This cuts much more cleanly, but it's slow. I can't take much material off with each pass. After that, I use a file to straighten the cuts. Then finally, I finish up with a 320 grit wet/dry sand paper. This does a decent job of cleaning the edge up, but it takes a light touch. So, that's one heck of a process for a single cut!

Time to cut! I used a yardstick as a straight edge, and followed up with my line taping method.

http://losias.net/projects/osidias/pictures/p6250351.jpg

An hour later I had two sides done... This is gonna take a while. Lol.

http://losias.net/projects/osidias/pictures/p6260352.jpg

[x88x]

Yes, it's a pain to work with, and yes, that's a lot for each cut...but damn that stuff is pretty. Probably a lot higher shear strength than straight CF too.

[StormRider]

wow, now your case is probably bulletproof:devious:

[craigbru]

Yes, it's a pain to work with, and yes, that's a lot for each cut...but damn that stuff is pretty. Probably a lot higher shear strength than straight CF too.

Yes, it's higher strength, but definitely overkill in this usage. :D


wow, now your case is probably bulletproof:devious:

Lol, it likely is. :up:



Okay guys, I had to make a little time for something unrelated to carbon fiber. It also has nothing to do with actual modding. What follows is just an example of why I've said that the planning for the case is only about 95% finished. Little things like this are always changing and being added. I live for the little details that some take for granted.

So, what we have here is an integrated heatsink for the water pump. It also doubles as a vibration proof mount for the pump via grommets. Once in place, air from the radiator fans will help with the cooling.

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump1.jpg

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump2.jpg

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump3.jpg

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump4.jpg

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump5.jpg

http://losias.net/projects/osidias/pictures/osidiasv1-4-pump6.jpg

This heatsink will make it's way to my CNC machine in the future. You can also see that I've changed the interior parts over to carbon fiber. Creative mold making will be coming!

[x88x]

Interesting. Are you expecting your pump to generate a lot of heat?

[SXRguyinMA]

I was wondering the same thing. my pump never really got that hot to begin with :?

[craigbru]

Interesting. Are you expecting your pump to generate a lot of heat?


I was wondering the same thing. my pump never really got that hot to begin with :?

The pumps is a DDC 3.25 (18w), and they can run a little warmer than the previous DDC's. Not that I really expect it to get that hot in the first place, but this gives me a great mounting system as well as ensuring hear will never become an issue in the first place. With all the components in this case so close together, it sure can't hurt.

[Luthien]

Rather you'll really need the help with keeping the pumps cool or not, the design looks good.

[x88x]

I have one of the 18W DDC's, and I can personally vouch for it not getting hot at all. And I run mine 24/7.

[craigbru]

Rather you'll really need the help with keeping the pumps cool or not, the design looks good.

Thanks man!


I have one of the 18W DDC's, and I can personally vouch for it not getting hot at all. And I run mine 24/7.

I killed a DDC on my L.O.S.I.A.S. project due to heat (at least it appeared so). It just happened to be the Thursday before a weekend LAN. I managed to get a replacement overnighted to me so I could get my game on, but it wasn't cheap. So, anything I can do to ensure reliability is a good thing! :D

[msmrx57]

killed a DDC on my L.O.S.I.A.S. project due to heat (at least it appeared so). It just happened to be the Thursday before a weekend LAN. I managed to get a replacement overnighted to me so I could get my game on, but it wasn't cheap. So, anything I can do to ensure reliability is a good thing! :D


Overkill on something like that is never a bad thing. Besides it'll look killer. :up:

[mofo]

my ddc 18w, tends to run fairly warm, hot even at times.

Also the pump introduces heat to the loop, so for overkill why not cool the pump. :devious:

[StormRider]

Overkill on something like that is never a bad thing. Besides it'll look killer. :up:
that's the "kill" in overkill

[Luthien]

Better to do overkill than to overheat. I put extra fans in my case when I discovered I'd have enough room for them.

[craigbru]

my ddc 18w, tends to run fairly warm, hot even at times.

Also the pump introduces heat to the loop, so for overkill why not cool the pump. :devious:


that's the "kill" in overkill


Better to do overkill than to overheat. I put extra fans in my case when I discovered I'd have enough room for them.

Lol, exactly guys. Overkill is fun!

[craigbru]

For anyone that has been following the project details closely, you'll have noticed I've got quite a few holes that need to be cut in the exterior of the case. Since I tend to try for perfect execution, I needed a very reliable and accurate method of marking those holes out on the case. I used the following method on the Rogue with great success, and will continue it here.

This is a transparent adhesive sheet used for printing labels. It's simply a matter of printing out the guidelines, which is made even easier since the entire project was designed in CAD. If you look closely, you can see an additional guideline extending to the left and right on the lower part of the design. This will help in placement.

http://losias.net/projects/osidias/pictures/p6150349_0.jpg

Next was the matter of proper alignment on the case. While it's pretty easy to place the sheet, I triple checked the measurements since they had to be perfect.

http://losias.net/projects/osidias/pictures/p6150350_0.jpg

With the adhesive label in place, it was time to add my masking tape guide lines.

http://losias.net/projects/osidias/pictures/p7120356.jpg

Time to break out the Dremel! I had to take it slow and steady here. You can't exactly fix any miscuts or slips... Even so, I managed to make quick work of the carbon fiber, and was soon left with a rough cut.

http://losias.net/projects/osidias/pictures/p7120357.jpg

After some filing, and sanding, I was left with the finished hole! My patience paid off, and I was left with a hole that was visually perfect to me. Now I've only got about 6 more to go.

http://losias.net/projects/osidias/pictures/p7120358.jpg

[x88x]

Nice! I love the seamless CF in this project. :D

[Couch3ater]

Holey moley. O.o Hahaha, I couldn't resist.

[craigbru]

Nice! I love the seamless CF in this project. :D

Thanks bro! Going seamless was a big deal to me. It's made for some minor complications, but the end result will be worth it.


Holey moley. O.o Hahaha, I couldn't resist.

Lol, that's terrible... :facepalm: :D

[SXRguyinMA]

lookin good!

[Luthien]

Looks good

[Loki]

Great work my friend!! And you have made one perfect cut over there!! congrats :D

[craigbru]

lookin good!


Looks good


Great work my friend!! And you have made one perfect cut over there!! congrats :D

Thanks guys! I do appreciate it! Speaking of cuts, I've made a few more...

I did stream live last night guys. How's that for brave? If I screwed up, I couldn't hide it. :D The 3 newest video's were recorded July 14th and 15th. You can see me cutting the holes out in the carbon fiber. There were only a couple times I had any real binding with the Dremel disk, but a firm grip helps keep things under control.

http://www.livestream.com/losiastechnologies

I've only got a few pics here, as the process for each hole doesn't change. Mark, cut sand. It's progress though!

In this pic I had already cut the second hole in the case. You can see video of that on the livestream link above. I've also got the hole marked out for the Aquaero.

http://losias.net/projects/osidias/pictures/p7150354.jpg

After cutting, I was left with another pair of holes. Now only 4 more to go!

http://losias.net/projects/osidias/pictures/p7150355.jpg

http://losias.net/projects/osidias/pictures/p7150356.jpg

[x88x]

Great work there. Smooth, seamless holes. :D

[StormRider]

and they're angled too. sweet work

[SXRguyinMA]

:stupid: it's looking better and better every day!

:EDIT: enjoy you're 5th green bar sir!

[craigbru]

Great work there. Smooth, seamless holes. :D


and they're angled too. sweet work


:stupid: it's looking better and better every day!

:EDIT: enjoy you're 5th green bar sir!

You guys are too kind! Thanks! I'm really taking my time with the cuts, and it's been paying off. :D



Well guys, I made a few more holes tonight. I was also streaming live again, so be sure to check out the Livestream (http://www.livestream.com/losiastechnologies) for the newest videos. (Be sure your volume is turned down a little, as the mic seems to be working a little too well...)

So, let's get this started! Here you can see the freshly cut hole for trio of 60mm fans that will sit over the video cards. This makes for 4 holes done, only 3 to go!

http://losias.net/projects/osidias/pictures/p7150354-2.jpg

http://losias.net/projects/osidias/pictures/p7150355-2.jpg

At this point I decided to clear up a question or two regarding this case's strength. I was trying to think of a good way to convey how strong the carbon fiber really is. You can see with the holes cut out, there really isn't a large amount of supporting material left in the lower part of the case. Well, I'm telling you that it doesn't matter in the least. Here you can see my daughters full 103 pounds being supported by the case. There's nary a flex! I can guarantee that aluminum would not have fared so well...

http://losias.net/projects/osidias/pictures/p7150356-2.jpg

With the case still in one piece, it was time to get back to cutting. For those that were following the planning thread, you'll remember that the windows on the side panels will actually be transparent LCD's. In order to get them to fit correctly, I've got to get a hole put in each side of the case for the circuit board. Here I've got the hole all marked out.

http://losias.net/projects/osidias/pictures/p7150357.jpg

The rough cut done!

http://losias.net/projects/osidias/pictures/p7150358.jpg

I'll have more in the coming days, so until then!

[msmrx57]

AWESOMENESS!!!!! And yup, bullet proof.

[x88x]

Wow, impressive structural strength even with all those holes gone. That's quite encouraging. I think I'm definitely gonna be using this method at some point in the not-so near future (ie, probably not in the next 2-3 years but hopefully within the next 5) for some of my vehicle ideas. ...oooh, I just had an awesome idea...dang it, why do so many of my awesome ideas have to cost so much? :(

[craigbru]

AWESOMENESS!!!!! And yup, bullet proof.

Lol. Maybe I'll test one of those scrap pieces for bullet resistance. I've got a .22 and a 12 gauge. :D


Wow, impressive structural strength even with all those holes gone. That's quite encouraging. I think I'm definitely gonna be using this method at some point in the not-so near future (ie, probably not in the next 2-3 years but hopefully within the next 5) for some of my vehicle ideas. ...oooh, I just had an awesome idea...dang it, why do so many of my awesome ideas have to cost so much? :(

Yes, it is pretty impressive, and only at 2mm thick. Lol, it's worth using if you have the means. Your brain doesn't factor in cost when it comes to ideas unfortunately.

[Luthien]

I heard the stuff was strong but I didn't know it was that strong...impressive.

[craigbru]

I heard the stuff was strong but I didn't know it was that strong...impressive.

I'm pretty sure I could have added more weight too. I wasn't interested in finding the breaking point though. All I know, is that it's far stronger than I'll ever need.

[craigbru]

Okay guys, I'm looking to live stream some work tonight. It will most likely be between 8~11pm central standard time. You can catch the stream at either of the following two links. One is on my site, the other is on the Livestream site. Either will be the same, and commenting during the stream is easy, although I won't likely respond to much until I'm done working.

http://losias.net/losias-live/

http://www.livestream.com/losiastechnologies

Since I do things on the fly, I usually record in segments. It keeps the filler and wasted screen time to a minimum. Also, no one really wants to sit down and watch a 2 hour video. I try to keep most under 30 minutes.

So, you can feel free to check either link at your convenience. Also, one of the easiest ways to see when I'm streaming is to follow my twitter feed. It's @craigbru'. I usually send a message when I'm about to go live.

Tonight I plan on finishing up the rest of my case holes!

[craigbru]

I got about 2 hours worth of streaming in last night guys. Unfortunately I've got no still pictures of my progress. I did manage to get the other hole for the LCD circuit board done, as well as the hole in the top of the case. I've got one more hole to put in the left side for the PSU, and then a small hole in the bottom of the case for ventilation on the pico-itx board that will be located there.

http://livestre.am/glpt

http://livestre.am/gl6b

http://livestre.am/gkTY

[craigbru]

Someone at XS asked me for an overview of how the wireless networking and control was set up in this machine. Since I took the time to answer him there, I thought I'd post it here as well for those that might be interested.

Okay, here's a brief overview of the wireless networking and monitoring setup. It's sometimes a little hard to wrap your head around, but I'll try and give a clear explanation.

I've basically got 3 complete computer systems in this case. I've got the main system consisting of the Asus matx board and associated components. Then I've got a Via pico-itx system acting as an always-on file server, and information monitor. Finally, I've got the Viliv UMPC that sits on the front of the case. These 3 systems are connected by both an internal ethernet hub, and an Asus wireless access point. The wireless network is used for information sharing and control by the Viliv. The Viliv is obviously a wireless only connection, but the other systems can connect either wired or wireless, and be independent of any other system.

Since the pico is always on, it serves to relay most of the system information. It will be attached to an Aquaero and Multiswitch, which in turn is responsible for all watercooling, temp sensors, and lighting. It will also allow me to turn the main system on and off through the Viliv. All the information I need on the Viliv will be relayed using a Samurize front end. Samurize's own network monitoring functionality, as well as the Aquaero software will allow for real time monitoring of the pico and main system functions. Now, of course since the Viliv is wireless, and always connected to the OSIDIAS network, I can just detach it from the case and use it as a remote.

Does that help explain things a little? Feel free to ask if it doesn't.

[x88x]

That...is gonna be awesome. :D

[craigbru]

That...is gonna be awesome. :D

Thanks bro!

One more thing... It's just occurred to me that there are probably quite a few of you who didn't see my planning thread for this project. If that's the case, you may have a few questions about the Viliv UMPC that I mentioned above. To allay any confusion, below is a pic and a link.


http://losias.net/imagehost/images/34251004s01s.jpg

http://www.myviliv.com/eng/product/x70ex.asp

[craigbru]

Thanks to inspiration from Javi, dbradford, and w33dy at the Mod Brothers forums, I've done a little something to help with my dust collection. I really needed a third hand when cutting on the workbench, and with none in sight, I came up with a great alternative. I modded an old architect lamp!

I couple of velcro straps, and the vac hose was attached to end of the arm. After using it for a few cuts, I've got to say that it's quite effective for a low tech solution. I'm guessing it's catching at least 75% of the dust caused by cutting.

http://losias.net/projects/osidias/pictures/p7270355.jpg

http://losias.net/projects/osidias/pictures/p7270354.jpg

So, with a decent dust collection solution in place, it was time to put it to use. I was streaming live (http://livestre.am/gPQm) during a portion of this, so I'm missing a few pics. With most of the side holes done, it was time to move to the top. Here is what it looked like after cutting.

http://losias.net/projects/osidias/pictures/p7270356.jpg

http://losias.net/projects/osidias/pictures/p7270357.jpg

Now it's time to move back the side. The last hole I need to cut is where the PSU will sit. Here is the hole all marked out. (Live Stream) (http://livestre.am/h8Jb)

http://losias.net/projects/osidias/pictures/p7270358.jpg

All cut! (Live Stream) (http://livestre.am/h8Ti)

http://losias.net/projects/osidias/pictures/p7270359.jpg

And finally a test fit with a PSU in place.

http://losias.net/projects/osidias/pictures/p7270360.jpg

[shugz117]

This is looking sweet 8) keep the updates coming:D!:

[craigbru]

This is looking sweet 8) keep the updates coming:D!:

Thanks man!



Update time! Today we pick up with the start of the interior assembly. Since I'm a glutton for punishment, I've decided to make the entire thing out of a single piece of molded carbon fiber. Since the dimensions have to be perfect, I am going to be using a two part mold. An inner and outer layer, with the CF sandwiched in between. In order to pull this off, I've got to do some very careful measurements, and even better cutting.

I'll be using 1.5mm aluminum for the molds. Here you can see a 4' piece marked down the center. I should be able to get both an inner and outer mold out of this 2'x4' sheet.

http://losias.net/projects/osidias/pictures/p7290354.jpg

Next up I've got to mark out all my cut and bend lines. There is no room for error here. Everything is down to the millimeter.

http://losias.net/projects/osidias/pictures/p8050355.jpg

After the rough cuts were made...

http://losias.net/projects/osidias/pictures/p8060356.jpg

After spending a maddening long time with the aluminum in my metal brake, I was left with the following. Mind you this was a little tricky, since it didn't exactly fit in there very well after the first few bends...

http://losias.net/projects/osidias/pictures/p8060357.jpg

http://losias.net/projects/osidias/pictures/p8060358.jpg

Now it was time to stick it inside the case for a test fit. I had no doubt everything would line up, but it's always a good idea to double check.

http://losias.net/projects/osidias/pictures/p8060359.jpg

http://losias.net/projects/osidias/pictures/p8060361.jpg

Next up is the outer mold. Once that is completed, I'll rub down the aluminum with release wax, and play with a little more carbon fiber. Woohoo!

Also, as of this morning, I've learned that OSIDIAS was nominated for bit-tech mod of the month! I'm honored!

http://www.bit-tech.net/modding/mod-of-the-month/2010/08/06/mod-of-the-month-july-2010/1

[SXRguyinMA]

nice work! and congrats on the nomination!!

[Waynio]

This was the first time in ages it was an easy vote for me, the other mods were top notch but this is really pushing the boundaries of awesomeness :D:up:, keep it up Craig :bowdown::yellow_green:.

[craigbru]

nice work! and congrats on the nomination!!

Thanks man! I really wasn't expecting it. I thought there was no way I had enough work done to justify a nomination.


This was the first time in ages it was an easy vote for me, the other mods were top notch but this is really pushing the boundaries of awesomeness :D:up:, keep it up Craig :bowdown::yellow_green:.

Thanks bro! I appreciate the support. :D

[Luthien]

Congrats.

[craigbru]

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.

http://losias.net/projects/osidias/pictures/p8170364.jpg

After cutting...

http://losias.net/projects/osidias/pictures/p8170365.jpg

Time to get this thing bent!

http://losias.net/projects/osidias/pictures/p8170366.jpg

http://losias.net/projects/osidias/pictures/p8170367.jpg

http://losias.net/projects/osidias/pictures/p8170368.jpg

http://losias.net/projects/osidias/pictures/p8170369.jpg

http://losias.net/projects/osidias/pictures/p8170370.jpg

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

http://losias.net/projects/osidias/pictures/p8170371.jpg

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.

http://losias.net/projects/osidias/pictures/p8170372.jpg

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 2x4 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.

http://losias.net/projects/osidias/pictures/p8170373.jpg

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!

[Waynio]

This project is simply amazing Craig, loads of awesome metal work just to be able to do the CF, though to be honest if it was me making this I would also do an aluminium version from the metal work done or is that something you had planned anyway or will it become scrap alu :), anyway I'm blown away by the lengths you are going to with this :D :bowdown:.

[craigbru]

This project is simply amazing Craig, loads of awesome metal work just to be able to do the CF, though to be honest if it was me making this I would also do an aluminium version from the metal work done or is that something you had planned anyway or will it become scrap alu :), anyway I'm blown away by the lengths you are going to with this :D :bowdown:.


Thanks bro! To think, if I was going to just use aluminum as I had originally planned, I'd be done! Actually, I'm going to hold on to all of my molds. No scrapping here. I want to either be able to build replacement parts or another case should I want to.

[BS Mods]

You are an awesome metal worker that's for sure. I'm impressed with all the bends lining up right. I can't seem to do it right the first time.

This is a killer build. Love the CF. I'll keep watching!

[TheGreatSatan]

That's a whole lotta bending!

[x88x]

Awesome work, as always. :D I can't wait to see the interior piece done!

[diluzio91]

heck, after this is done i would bet you could sell a full CF case for a LOT of $$

[craigbru]

You are an awesome metal worker that's for sure. I'm impressed with all the bends lining up right. I can't seem to do it right the first time.

This is a killer build. Love the CF. I'll keep watching!

Thank you. The bending is the easy part. It's the measuring that's likely to cause problems. As long as you mark it out right, it's not so bad. It sometimes takes a little time to get everything lined up in the brake.


That's a whole lotta bending!

Lol, thanks bro! It definitely is.


Awesome work, as always. :D I can't wait to see the interior piece done!

Thanks, I appreciate it! Right now it's looking like late this weekend or the first part of next week before I get to lay down the fiber.


heck, after this is done i would bet you could sell a full CF case for a LOT of $$

I'm not sure anyone would be willing to spend the cash to make that happen. It certainly wouldn't be cheap. I don't know of any shortcuts here. It's all pretty labor intensive. Lol. I truly can't wait to finally put the CNC to use on this case.

[diluzio91]

It's beautiful so far

[craigbru]

Update time! I actually livestreamed the fiber going down, although it was a huge pain. For some reason I thought it was a good idea to skip taping the edges of the fiber. Needless to say those stray fibers soon became a problem as the layers went down. I managed to keep them out of the way, and got 5 layers on before I ran out of resin. That means I'm a layer short of what I wanted to be. Although looking at the finished assembly, it's likely thick enough, but I'm going to give it one more anyway. I had a little trouble sliding the outer mold in place. The resin kept sticking to the mold and pulling it down with it. Doh, why didn't I wrap plastic around it before the mold?! That would have taken care of the problem, and I'd be done. As it is, now I've got to sand and add the last layer anyway. Mostly for cosmetic reasons mind you. The outer mold caused some wavy weaves because of the sticky resin... and I just can't have that. I'm out of resin though, and will have to order more before continuing.

Well, enough of that. On to the pics! Here I'm using a template to cut out the layers of CF.

http://losias.net/projects/osidias/pictures/p8280365.jpg

Obviously I couldn't take pics while wrapping, but here is the mold all clamped up.

http://losias.net/projects/osidias/pictures/p8280366.jpg

Now it was time to see if that mold wax release was going to do it's job. I had a total of 3 layers on, so I was pretty confident. Success! The outer mold released without an issue. Here you can see the interior assembly in it's freshly released state. There are a few spots that didn't get completely 'covered' with resin, but it's hardly an issue. There was complete saturation and it's damn solid!

http://losias.net/projects/osidias/pictures/p8280367.jpg

Finally, I took the dremel and cut off most of the excess fiber. You can see the interior mold is still in place. There's a good reason for that. It is cut to the exact dimensions that the assembly needs to be. During the final cut down, I'll use the interior mold as a guide to make sure everything is cut correctly. Without it, I don't think measuring out where I needed to cut would have been so fun...

http://losias.net/projects/osidias/pictures/p8280369.jpg

http://losias.net/projects/osidias/pictures/p8280370.jpg

At this point I've got to get some more resin ordered. In the meantime I'll sand down and prep the interior for the last layer of CF. Then I can start making holes in it for all the components and wiring. Woohoo!

[Luthien]

I really checking in on this project every so often. It's cool to watch all the cf take shape.

[x88x]

Wow, yeah, those extra fibers were kinda scary before you cut them off. :P

It looks good; I can't wait to see it after the last layer and it's cut to shape.

[craigbru]

I really checking in on this project every so often. It's cool to watch all the cf take shape.

Yeah, I've got so much more fiber coming too! Everything inside will be molded from it with the exception of the motherboard tray.


Wow, yeah, those extra fibers were kinda scary before you cut them off. :P

It looks good; I can't wait to see it after the last layer and it's cut to shape.

They definitely were, Lol, I've got a mess in the shop now!

[SXRguyinMA]

Update!!!!! Now!!! :d

[x88x]

I was actually just wondering yesterday what happened to this project. Any updates, craigbru?