Mould finished, lamination started

After the mould is complete, the carbon fibre lamination phase begins. This is getting a real fun now!

First, the carbon sheets are cut and inserted into the mould. Then the laminated mould is inserted into a airtight bag and connected to a vacuum pump. The pump will press down the carbon fibre sheets to the mould and suck in the reisin which will fill up the gaps between the carbon fibre and harden the structure.

Enjoy the pics and VOTE FOR MY PROJECT and help me get to the orbit! Thanks!





Moulding the wooden model

The fun begins!

I will try to describe how the mould is created in step by step…

1. After the wooden model is finished (I could easely spent another week polishing this out but there is no time for being a perfectioninst), I can proceed with creating the mould which will be used to laminate carbon fiber.

First, the model gets fully covered with plastic tape. It will prevent the wooden model to get damaged when removing it out of the mould. It is then placed on the plastic surface. On the top there is a vertical splitting plane which will split the mould in left and right part.


2. The next step is to cover it with a gel coat. This thing will pick up every small detail of the model’s surface.

I love the color!



The gel coat is added to the model’s surface. Oh did I mention how I love the fluo green color?  The gel has this color to be well distinguished from the model’s surface so you can check out if you left out a small part somewhere.



3. Then, the moulding mass is getting prepared.. dirty job! This mass is then poured with Araldite which hardens the epoxy.


4. The dirty mass is then placed around the wooden model..


5. Then the mould is left overnight to dry.


Now I cant wait to see what will come out..:)


Mold #2 in progress..

Well well well. Things ain’t going always well. Styrofoam mould, the first version I have made is not what it should be and I am a bit dissapointed about how it looks.  Styrofoam itself is also very soft and fragile material which makes it difficult to work with.

I am now fully into creating a new, wooden mould. But, without the access to any kind of CNC machine or 3D printer which would help me big time, I am building it with my hands and Dremel Micro…

Hopefully tomorrow I will have the mould ready so I can start with lamination of carbon fibre.




Styrofoam cutter

One of the side projects is the creation of syrofoam thermal wire cutter. Styrofoam is very tricky to work with. It is soft and granulated. Rougly it san be cut with a wood saw but for fine cutting you need something more precise. Styrofoam melts under high temperatures so the heated up wire is a perfect tool.

The Wire

The wire material must have a high specific electric resistance. Some electric resistors used in electronics are made from a special “resistance wire”. I have found a pack of resistor wire in Conrad electronic shop. The wire is 0.35mm in diameter and has a resistance of 10Ohm/m.

Power Supply

I have used an old PC power supply. On 5V, the wire at 20cm lengh heats just right! Measured with a multimeter, it draws arround 3Amps on 5V.

The finished cutter

Some wood, some glue and 15min of time. Wood elements are cut with Dremel Micro which is really a great tool for such quick and small jobs. The cutter works like a charm 🙂

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