I was planning to make a giant 2 part mold and park my car on it, 6 layers of Canadia maple veneer and 2 layers of fiberglass (no idea what types or thread count yet) on the 2nd and 7th layers… probably hot water pre form then paint each with Titebond III, then epoxy the FG layers in
Can you elaborate on what cross band layers means?
I’m aiming for some flex but no twist if at all possible
Cross band has grain going the opposite way of standard veneer. So the grain goes perpendicular to the length of the board. This adds thickness without stiffening the board. It also adds strength in the width of the board.
Those fiberglass layers do the same thing but will add some stiffness. How much will depend on where they’re located and how strong they are.
The deck flexes and the bottom layers see tension forces. So strong tensile strength items near the bottom of the layup will have more effect on adding stiffness than one on top of the layup will.
Make sure you own a router and a jig saw.
Complex curves are challenging. The Bustin’s poster has a drop down and where that bend in the deck occurs intersects the concave portion of the deck. That’s a challenging section of the deck to form to because the wood is bending in perpendicular directions in the same or near by spaces. Those areas will take increased clamping forces to overcome
Parking on top of it probably won’t work. You need and even distribution of the load and I’d bet a dozen screw clamps would create more clamping force than a single car tire and partial weight of the car. Some pieces of angle iron steel might help as well. Forming the whole deck at once will take a lot of force. Adding moisture and heat changes a lot, but introduces other problems too
Do you have any suggestions for how I should do layers? For reference I’m only 120lb and I’m aiming for around 1.5" of deflection on a 39" board by shifting my weight up and down
(Top)
In terms of pressing, I guess hot water, press (ass load of clamps), wait to dry, lather in glue, press again, epoxy GF, press a last time, cut out (I think I’ll have access to a 4’ square CNC, then card down fabric?
The orientation and number of layers will depend heavily on the the of material and thickness.
You’ll go through a few decks worth of material before you have your press totally dialed in. I’d start with about a 10-12mm thick total layup and see where that lands you. But that’s just a guess
If you have a 3D printed and are planning to design this in CAD, you could take slices of the board and print those as thin templates for drawing the shape to your mold
Used 1/16th maple from Roarockit and west system epoxy. did a weird exterior jig with the veneer in a bag and clamped to the jig… there are pictures.
Roarockit is super helpful and I love their company, only downside is shipping can be a bit much because they are north of the border in Canadia
Ooh I totally forgot about your raceboard, have you sourced materials yet?
zach watch this… it’s resin-infused, but it covers a lot on buck design, layups, strength, zac. bagging etc. worth the watch…
Awesome, will do!
Hmm, so I think I need a ton of diagonal and cross wise fiber directions…that should allow for flex but minimal twist?
I just found this composites layup calculator, it seems to let you calculate different orientations of fibers.
https://www.efunda.com/formulae/solid_mechanics/composites/calc_ufrp_abd_layout.cfm
I’m not sure if a standard weave in diagonal direction will give you flex the length direction or if the combined opposing angles would effectively do the same thing
holy shit…
the internets is a wonderful thing!!!
thank you for sharing Ryan!
I guess I make tiny index card sized tests and get a reliable reference for flex and twist and fuck around until I’m happy? It’s science if I write it down isn’t it
Make it. Take notes. Test it. If it’s too bendy, add more layers. Retest? Science
Have you looked at the MasterCHO deck builds from the old forum, he has notes about the no and types of fabric he used and video flex tests for some decks. He also looks like a featherweight too, so layup might be similar
Damn, that was like porn but its SFW
Will watch after work with my pants down.
It is decidedly so
