Evolutionary

[Franklin]

It's a very small update, but I'm so happy with the result. It's a nasty stuff to work with but the result is very good.

Later today I'll remove the polyester model from the clay model and cut down the edges.

Thanks everyone for all the comments and the rep points.

[Franklin]

The polyester is removed from the clay and it looks very good. I didn't know what I could expect from this material but I'm very satisfied with the result.

So this fibreglass part I will use as a model for the 4 parts I will use as airoutlets. The inside of this model to be precise is the side I will use as the model. Just add some special black paint to the resin to get a black part.

[Franklin]

I almost finished the 4 models for the airducts that will be placed on top of the case. These models will be sanded and painted later after they have been attched to the polyester top that wil cover the upper part of my case. I wanted to show where these parts will be mounted.

Also worked on something for my dustfilters. It's always difficult to get those things out and that's why I want to create something that can easily be removed. I will use three layers, two will be glued together and the third is just to keek the filter in place.

I will mount a profile underneath my case where this thing will slide in. Far from finished, will have to file it, corners wil be rounded and it will have to sanded.

[Franklin]

Started working on the fibreglass that will cover the top of the frame ( the top and about 17 cm. of the sides )

It's a dirty stuff to work with. You've got to work fast because it gets more and more sticky after some time.
The model that will be covered with the fibreglass is finished. Around the model I mounted a wooden frame. When the fibreglass is hardened I can push the model of. If this doesn't work I can always remove the MDF from the inside.

Before I can begin I have to cut the glass mats into the right size.

Right now there's are four layers of glass.

Tomorrow I can put on the last two layers. After this is finished it will have to harden. When it is dry I will cut out some areas for the airducts that I already have made. These ducts will be mounted with some fibreglass to the big model and with some special bondo for fibreglass it will be smoothened so you can't see that it were seperate parts.

The part I am making now will be placed over over the frame, here.

Afterwards I need to cut out some areas for the ducts.

[Franklin]

The fibreglass hood came of the MDF model without any problem and the inside is perfectly smooth.

I testfitted the hood over the aluminium frame and it fits. Could not wish for more. No image of the hood over the frame, the battery of my camera will have to be recharged first The outside has to be sanded. After that I will cut out some areas for the airducts and some other things.

[Franklin]

Thanks for your comment and the rep

Here is the image from the hood over the frame. It needs lots of work, sanding, need to cut out some areas for the airducts and for some other things. When this all is finished it will be painted. The fibreglass at the bottom sticks out, but that will be removed so no problem at all.

This week I will be working on two other pieces of fibre glass that wil be mounted in this big hood. An image will make it more clear I think. The areas that are marked in black will be removed from the fibreglass.

The part in the left corner will be made this week and will also be fibreglass.

In the end it will look something like this.

In the openings I will place some acrylic, just like in the sketch some pages ago.

[Franklin]

I was inspired by a building in Sydney Australia last year

The only place I can cut the polyester is outside in the garden because cutting or filing it creates an enormous dustcloud. I have to wear a mask and after work I just have to take a shower to remove all the white dust.
First mark the area that I'll have to cut away with my Dremel. The openings for the fibreglass airduct will be cut later on, after finishing these parts.

I didn't know if it was hard to cut the fibreglass so I took some distance from the marking. In fact it was easy to cut, but to be on the safe side I don't cut on the marking.

This is the model for the fibreglass part that I will create this weekend.

Keep the model in place, ofcourse this will also be fibreglass, but just to see what it will look like.

I had to draw an ellips. Need one half of this ellips to mark the lower opening for the airducts.

[Franklin]

It's nice to be on the frontpage, thanks guys

Ready to make two more fibreglass parts. I need two of these parts for the right side and the left side of the case.

The parts came of pretty well. Only need to cut of some material at the edges. I leave some material at these edges for mounting it to the big fibreglass part I made earlier.

With an ordinary Dremel I cut away all the stuff that isn't needed. Quite a dusty job. I wear a mask and work outside as you can so.

Later on I will draw the ellipses on the parts and cut them out.

[Franklin]

I bought a cheapass electrical sanding machine, because I have to smoothen te surface from the lit. By hand it would take me ages. I'm glad I bought it, because it saves me lots of time.

The top of the case is almost ready, the sides will be done next days. Ofcourse I wear a mask while working on it. I almost look like a snowman after sanding :brrr:

When all the sides have been sanded I will use a special kind of bondo to fill up every little hole and wetsand it afterwards. To be able to cut of the small airducts straight my dad made something for me. Now I can saw it and all the airducts will be the same size.

Worked great. Now I can mark the lit. This has to be cut of for the airducts.

The holes look a bit big, but when the airducts are placed it already looks a bit better.

and that's not all, I will also create some sort of fingergard from acrylic. Looks fantastic, but you will have to wait for that.

[Franklin]

I cut some holes in the lit for the airducts with my fake Dremel.

I numbered the holes and the airducts, it's all handwork so there all the ducts are slightly different and fit only perfectly in the hole with the same number.

After three days of bondoing and sanding the lit is almost smooth. I will need to wetsand the lit one more time.

I want to glue the airducts to the lit and want to use some UHU 2 components glue for this job. On the UHU website it says

Metals, glass, porcelain, ceramic, wood, marble, stone, concrete, Duroplast®, glass fibre reinforced synthetics, rigid PVC, rubber, rigid foam plastics such as Styropor®. Not suitable for sticking large areas of glass.

So I think it will work, but to be sure I will try it on some leftovers first