Fibreglass : Mold and Enclosure Making : How To and How Not To

I’m planning on trying to vaccum form a segmented fiberglass enclosure and have a few questions:

  • Is it really worth making a negative mold for only a single enclosure and instead using a positive mold technique kind of like what is shown below and (if needed) coating the outer surface with a fumed silica and epoxy gel coat and sanding it to get a nice finish?
    https://electric-skateboard.builders/t/segmented-carbon-flex-enclosure-for-trampa-urban-carver/20067

  • Also, is 600 gsm woven roving conformable enough to lay between the segments of a buck/enclosure along with some 250/300 gsm cloth? Using only that thinner cloth is going to take a lot of layers.

Anyways, thanks everyone and especially glyphiks for the tons of helpful information on this thread! :sunglasses:

Depends on your desires for finish quality. And effort you want to put into its appearance and finish.

Negative mould can mean almost no post finishing for a perfect finish (but it’s lots of work to get these)

Straight out of the mould (small defects from problems with the shape):

Positive buck vac bagged can still be good. Way less work.

Perforated plastic film can leave a nice texture on a vac bagged part, but with segmented shape it it will be hard to avoid creases in this or the peel ply (not perfect smooth).

My first ever self taught carbon fibre project. Layup on positive buck, vac bagged with perforated plastic then peel ply and breather layer. It got stuck and I beat the shit out with everything I had to get it off the buck. You will see where it is broken.

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It is ridiculous to go to that much effort for a single enclosure unless you want the experience, or think there is a possibility you want to create another at some point in the future.

I just popped this out of the mold this morning. It is super satisfying popping it out of the mold :joy: but its a metric fuck ton of work.

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(or more)

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thanks @rosco and @dirtsurfer @glyphiks

I’ll do my decks as positives… but the enclosures I shall make a negative mold and just keep the same board profiles where the battery is located…

you kidz are inspirational…

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Hey, can I get some input on this? Thanks!

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what does the segment look like size wise?

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The enclosure will have two segments that are about 50mm tall and there is about 8mm of space between the segments. Also the corners/edges will be rounded and all of the sides are going to be angled.

If it were me, I’d be putting 2 layers of roving in a cloth sandwich for that.

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Yes, that’s the plan. Going for a look like eBoosted’s segmented enclosures

Roving might be hard to get to cooperate in that situation. You’ll probably be better off with several layers of light weight chop strand.

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Hmm… I’m going to use epoxy so regular chopped strand mat isn’t going to work. Would it be fine to use that roving and just put a bunch of relief cuts? Other than that, I would have to use several layers of 250/300 gsm cloth to get a good thickness, which is going to use more material and be more expensive.

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Personally, I’d use the cloth. Fighting with a wet layup is no fun at all.

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I know that @J0ker just did something similar. He may be willing to share some nuggets of knowledge.

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Great, I’ll just get the roving and the thinner cloth and try using them together for science. It’s going to be vacuum formed so I imagine that there wouldn’t be that many issues with doing a lay up like that.

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Ahhh vac form is a different story. Roving will be fine.

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So the enclosure I was doing was a diy hs11. Had 4 sections with passages to each section for series connections. I used FB mat. Would’ve have worked if I hadn’t of been lazy and wrapped the buck. It wouldnt let go of the epoxy. I may have been overly medicated on thc lol.

Epoxy will work with enough layers. Just dont be lazy with it. The first epoxy enclosure I did was for La Ferrari and it’s still sound with no cracks. Needs a fresh clear coat though.

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What goes on eBoosted enclosures that makes the surface finish so nice?

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My guess is bed liner paint or similar.

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Yea probably. This is from 2017 btw

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