Racey
Maxwell Smart-Ass
- Joined
- Sep 18, 2007
- Messages
- 21,308
- Reaction score
- 45,375
This resulted in a complete failure half way through, but eventual success and a lot of learning along the way.
Helmet air ducts.
First wax the helmet and pop a laminate in the area we are going to use, this gives us a thin structure of our helmet shape.
Epoxy our rough duct shape into place, this is just a piece of grey plastic conduit that i heated and roughly bent into a slight curve then cut and bedded in epoxy thickened with silica.
Grind and cover with epoxy thickened with fairing compound (easier sanding more like bondo but epoxy based, the silica is very strong and hard to sand)
Sand into shap by hand, you can see where the silica portion peeks through in some areas, it is much much more difficult to sand.
Cover in gel coat.
Sand and fair the gelcoat.
Waxed and then attempt to pull a mold off this plug and completely fail
Helmet air ducts.
First wax the helmet and pop a laminate in the area we are going to use, this gives us a thin structure of our helmet shape.
Epoxy our rough duct shape into place, this is just a piece of grey plastic conduit that i heated and roughly bent into a slight curve then cut and bedded in epoxy thickened with silica.
Grind and cover with epoxy thickened with fairing compound (easier sanding more like bondo but epoxy based, the silica is very strong and hard to sand)
Sand into shap by hand, you can see where the silica portion peeks through in some areas, it is much much more difficult to sand.
Cover in gel coat.
Sand and fair the gelcoat.
Waxed and then attempt to pull a mold off this plug and completely fail