Mock up.
Result is ok, but a few flaws in hand layup (ran out of time), so vacuum infusion is the next step.
13 Likes
But Ross… do the cells fit? 
Looks fucking epic dude. I have loved watching this journey 
2 Likes
They fit.
Don’t have any spares but they will.
If I can get infusion to work, part will be thinner and have a bit more breathing room. It’s tight.
Template
8 Likes
When you get your shit sorted, I want one. Such a good looking enclosure.
3 Likes
You guys rock.
You should make a video though, I read this on one take and my head is still spinning 
2 Likes
Make sure to mix it up properly
Now quick its curing!
2 Likes
I didn’t understand this part 
how did you make that black concave piece and how to transform the wood from flat to wrap around that?
For the places where the wood mold has a gap to the deck did you use clay or something like that?
1 Like
The black piece is just 3d printed. Its just a spacer between the segments designed to allow a space for wires to travel from segment to segment.
To fillet the gap between the buck and the deck, i used plasticine. Since then I have discovered filleting wax. It is far superior.
2 Likes
Oh I see. How do you solve the wood mold being flat and the deck being concave? I’ve seen someone on this forum that filled the deck with wood putty to make it flat and then made the mold, but wood prefer some approach that wouldn’t involve transforming the deck.
Thanks for the tip, will check it out!
In this instance, i didnt. I just filled the gap with plasticine and fibreglassed over it.
Since then, i have used a method of clamping multiple plies of glued mdf to the deck, to give the buck a bit more shape.
You can see one method that I used in this thread
1 Like
That resembles building a sk8 deck 
also thought about that but then the top of the enclosure will have that curve also which is not so good to receive a battery pack…
1 Like
Works fine. You either build the pack to suit the enclosure or build the enclosure to suit the pack.
Im a bit confused tho, didnt you just ask how to shape the buck to match the deck?
3 Likes
Yeah, I think I’m exaggerating this problem.
Ideally I would have a perfect flat base with a concave and curves matching the deck on the other end, but I guess that is not so easily doable.
Perhaps printing 3d TPU concave shapes along the deck and then putting the wood mold on top?
You’re overthinking it. Jam plasticine in the gaps and be done with it. It’s only there to give you a shape to fibreglass to.
3 Likes
What do you guys use to clean the brushes and rollers, to be able to reuse them?
I use chip brushes, one use, then in the bin.
For the other tools, clean them with acetone before the resin cures. Wear gloves.
3 Likes
White vinegar also works for cleaning uncured epoxy resin.
4 Likes
Wow! And here i’ve been wasting my expensive acetone 
2 Likes
Cool. You clean your brushes too or just other tools?