March 26, 2005

While at Purdue, Ryan was given a composites project for the race boat. The project was to build a portion of the shaft cover (in the cockpit) which would interface between the aluminum cover running under the seat and the firewall.

Based on his experience working with composites on the Purdue Solar Racing Team, this project was perfect for him, and could be completed away from the boat. (Ryan was project manager for the construction of the composite body for the car that semester.)

A plug was first made (based on dimensions taken from the boat) out of foam, from which an epoxy mold was pulled.

A carbon fiber & fiberglass wet layup was completed to make the part.

The part was such that it would flange under the rear and side pieces of the shaft cover, while having a lip on the forward end (large part) to be captured by the firewall.

Special thanks goes out to Steve Foulkes and Eric Aasen of the Purdue Solar Racing for their assistance in the project. A few extra sets of hands is always nice.

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Next: May 25, 2005

© Ryan Smith, 2003-2007. All rights reserved

Date: 03/26/2005

Owner: Dragon Keeper

Size: 13 items

Plug for the mold. High density foam end pieces, low density foam, hand contoured, center piece sealed with Bodo. Date: 12/13/2007 Views: 37	High density foam end pieces per firewall and shaft cover profiles. Date: 12/13/2007 Views: 35	Top view of plug. Date: 12/13/2007 Views: 28
Plug coated with enamel paint to provide a hard, sealed surface. Baked to ensure full cure in oven. Date: 12/13/2007 Views: 35	Epoxy thickened with cabosil and graphite powered slathered over the plug to create the mold surface. Date: 12/13/2007 Views: 37	Fiberglass reinforcement added to the outside of the mold to provide structural rigidity. Date: 12/13/2007 Views: 36
Removing the plug from the mold. Date: 03/19/2005 Views: 31	Carbon fiber & fiberglass cover laid-up in the mold co-curing with Purdue Solar Racing's SPOT II lower body under vacuum. Date: 12/13/2007 Views: 38	Size comparison ... Date: 12/13/2007 Views: 33
Vacuum trapped in the mold, and ready for the trip back to Cincinnati. Date: 12/13/2007 Views: 32	Cured part in the mold, prior to removal. Date: 12/13/2007 Views: 29	Final part. Note flanges on both ends to slide under the aluminum shaft cover, and to be captured by the firewall. Date: 12/13/2007 Views: 37
Date: 12/13/2007 Views: 37