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Old 03-27-2016, 03:35 AM   #11
petey1549

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Here's a few photos of what I was actually trying to build - a new basin for my milling machine enclosure.

I'm happy enough with the result, but I could have done a few things better. Been a long time since I worked with some of these materials so it was good refresher.
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Old 03-27-2016, 03:37 AM   #12
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Started with a foam form. Glassed with epoxy, a little body work then some epoxy primer. Sanded, waxed and pva'd before layup.
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Old 03-27-2016, 03:40 AM   #13
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laminate built with gelcoat, then glass cloth and chopped strand mat (polyester resin).
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File Type: jpg IMG_1829.JPG (1.66 MB, 19 views)
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Old 03-27-2016, 03:44 AM   #14
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I didn't maintain relief angles so I knew removing the mold was gonna be fun. I could have done it in a way that the mold would release without destroying it, but the added labor in mold construction wasn't worth it to me. I only need one of these parts and had no plans to keep the mold in storage.

Only a little coaxing was required to separate the part once the foam was removed from under the mold surface.
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File Type: jpg IMG_1836.JPG (1.50 MB, 16 views)
File Type: jpg IMG_1837.JPG (1.37 MB, 18 views)
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Old 03-27-2016, 03:54 AM   #15
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I ended up with some gelcoat alligator skin in a few places, but I had some problems when spraying the gelcoat that I wasn't able to remedy in time. Sprayed too thin cause I was low on material and my gun was giving me fits.

Would be easy enough to resurface a few of the bad spots, but I'm not worried about it.

Now the fun stuff, trimming, bonding it to the base and plumbing in all the coolant system parts. I've got chip trays yet to build that will sit in each basin. I'm anxious to see how it works and I've got my fingers crossed that coolant/machine oils/metal chips won't be too hard on the gelcoat over time.
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