t_vago's compound curve foam board pickup aeroshell

[skyking]

I am just reposting a store I read about in another thread.
Raka, Inc. 772-489-4070
A three quart kit from these guys should do the trick for you.

This cloth from the overstock section would do nicely.
Style 7544- 10oz x 50"
That is 10oz per square yard, but $4.00 per running yard. Figure on 5 running yards outside and 7 inside. 12 yards at 10 OZ x 1.3 = 156 Oz or ~10 pounds.
3 qts resin = ~6.6 pounds (epoxies are around 1.1 specific gravity and close to 100% solids)
You could dance on it afterwords.
3 qt kit is $39 plus $48 in cloth and some tools, and shipping. It will run you a little over $100. You need to cover that epoxy with a UV barrier or it will eventually chalk up over time. You could pigment it, but I would still paint over it with some good paint.

[Varn]

I used to use West system and the proset brands that gungeon brothers sold. I developed an allergy to it. In the last year I have been using US composites epoxy brand with excellent results and a somewhat lower price. I don't seem to react to the epoxy yet.

Please make some parts that are not structural and include overlap joints to test before you work on your nice shape. You will be glad that you did.

[t vago]

Don't worry about me experimenting on my aerocap. I have (literally) a truck-bed full of scrap FoamulaR foam material to experiment with.

[skyking]

My dad got sensitized to the West System epoxy back in the 80's. I had to finish his last boat for him. Of course things have changed, but I always use gloves.

[KamperBob]

Originally Posted by t vago

Don't worry about me experimenting on my aerocap. I have (literally) a truck-bed full of scrap FoamulaR foam material to experiment with.

Whilst playing with 1/4" pink-board I noticed the shinier side has a plastic film coating. I wonder it both sides react the same to polyester resin or how much difference that thin layer might make...

[CFECO]

Perhaps a use could be made of shrink wrap material. There are many different types, some of which are used for semi-permanent outdoor storage of equipment.

[t vago]

Originally Posted by KamperBob

Whilst playing with 1/4" pink-board I noticed the shinier side has a plastic film coating. I wonder it both sides react the same to polyester resin or how much difference that thin layer might make...

Unfortunately, that plastic coating has numerous holes spaced at regular intervals. At the least, polyester resin would seep through the holes and cause regular spaced gloppy holes in the 1/4 foam sheeting.

I am not sure if the Styropoxy would stick to that plastic. It should, if it's an epoxy-based coating. I'll find out once the Styropoxy comes in.

[CFECO]

http://www.youtube.com/user/AmericanShrinkwrap

[Varn]

You really don't need to worry about those holes or the peelable film. Just tack your cloth down and paint on the epoxy. If you end up with a strong enough part the foam can be dissolved out with gas or you can peel it off with a blade (hard way). If you only use one layer of cloth you won't have much structural integrity and will want to make sure that the foam stays in place.

How are you going to control warpage? Seams are where you are going to get most of it. When I made this type of contstruction I glued scraps of 1/4" pink board behind the seam and used the 2 part foam as glue. If it were mine, I would lay it up on the truck and use plastic sheeting to protect the finish and tires.

[skyking]

I was thinking about that myself, a couple of layers to be sure.