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Re: Toroid building

Original poster: "seanick" <edgarsbat@xxxxxxxxxxx>

it is actually very possible for someone who doesn't fit into the "talented" category to figure out fiberglass. I have made a few things just out of pure spite for the first couple failures I had. the only process I have learned to make work is, don't mix any resin until a form is completed, and the cloth is cut to size (use 4 times as much cloth as it looks like you will need - when you press it together it ends up a lot thinner than you think, 7 or 8 layers of alternating Matte and Cloth is less than a quarter of an inch thick...), and there is a way to vacuum out the air and/or apply a massive amount of pressure. Do it all at once, pour the polyester resin on quickly then spread it to the corners or whatnot, and apply the pressure. I used to try to make things in multiple passes but there are always air bubbles that way. Now I use a massive thing my roommate calls a "house jack" but is apparently for holding cargo in place in a semi, to press flat whatever I am working on, or sometimes hook up a vacuum cleaner hose to suck the air out of a box if the part is going to be a strange shape. sometimes you can use a thick balloon to press on some fiber project from the inside. the biggest thing is, press it so the resin goes through all of the fabric layers. once dry, sand the crap out of it with a dust mask, vacuum, hepa filter and whatever else you can as a way to keep the dust off you, and then apply a couple layers of gel-coat. sand those smooth, polish and you end up with something that looks like it could be used as a boat hull.

that doesnt really sound like it would work for a toroid, now that I read it back, so you would have to be creative. well, thats the fun in it I suppose..

----- Original Message ----- From: "Tesla list" <tesla@xxxxxxxxxx>
To: <tesla@xxxxxxxxxx>
Sent: Saturday, August 20, 2005 11:52 AM
Subject: Re: Toroid building


Original poster: Jim Lux <jimlux@xxxxxxxxxxxxx>

At 08:06 PM 8/19/2005, Tesla list wrote: 
Original poster: "Scott Hanson" <huil888@xxxxxxxxxxxx>

Jared wrote:

" Ez to do ...."

May I ask if you have ever actually attempted this yourself?

If so, could you post photos of the results?

Regards,
Scott Hanson
----- Original Message -----
From: "Tesla list" <tesla@xxxxxxxxxx>
To: <tesla@xxxxxxxxxx>
Sent: Friday, August 19, 2005 4:00 PM
Subject: Re: Toroid building


> Original poster: Jared E Dwarshuis <jdwarshui@xxxxxxxxx>
>
> Fiberglass cloth and polyester resin for the first layer then smooth
> with body filler and sand before second layer of cloth.
(snip)
> Ez to do but sticky and tedious.
>
> good luck from Jared



This technique fits in the "easy for some, difficult for others" class: like making oil paintings, doing body work on auto sheet metal, carving marble sculptures, cutting topiary, etc.

IF you have the right tools
AND
IF you have the experience or talent

it goes real fast and the product is great.

If not, it's tedious, horrible, the product is ugly.

I used to work with people building sets and props; foam, plaster of paris, and bondo (which is just a mixture of resin and chopped fiberglass) were their main tools. Truly amazing products (very realistic, good looking copies of famous statues, for instance) in remarkably fast time from skilled practitioners. For myself, though, I tried making a simple parabolic reflector using the same basic materials and techniques, and it was a gruesome failure. Main difference: they are artists, I am an engineer.