Dinghy Boat Plans
I was thinking of calling this port tooling around because that probably best sums up what Ive been doing for the last month. No-one cares about that though, instead Im going to run through the process for creating all the moulds needed for the new build.
Because I still have access to the CNC router - its now being housed by my mates at Street&Garden Furniture Co. - it was pretty straightforward to send every part, big or small, to it and create a set of female moulds. Detailed things were made in ply or MDF, and the large simple shapes were cut from Isoboard EPS insulation foam, recommended by the guys at CG. I designed the boat and made the 3D model so that everything would be able to be done this way, and it was super quick to pull parts out, create the toolpath and press print. I set up a new dust extraction system to deal with the polystyrene dust, and it works really well. didnt miss a drop.
Heres a photo of the setup, and another after a weekends of successful routing.
The bigger parts took an hour or two to cut, the smaller ones obviously were quicker. I had a couple of small issues cutting the foam where it melted etc, but thats boring so I wont go into it. Thick parts were made in layers 75mm thick, and then guled together with epoxy later. The rough-ish surface (3mm step) sanded back easily and I then sealed it with some epoxy and colloidal silica bog. Then another quick sand, another layer of thinner epoxy/silica, carefully applied with a credit card, and youre done! The moulds all held a good vacuum with no problems, important because you cant envelope bag it as it compresses the foam, and the surface quality was generally within range of high build. Its gotta be the quickest way to make large composite parts.
The MDF/ply bits are now pretty straight forward. Ive learnt that its better to cut them with a much finer stepover (1.2mm or so) so that you almost dont need to sand them. It takes a bit longer on the machine, but saves you lots of stuffing around later. Then one coat of resin and a sand and theyre good to go. The foil strut mould was the last thing I did, and turned out the best.
Because I still have access to the CNC router - its now being housed by my mates at Street&Garden Furniture Co. - it was pretty straightforward to send every part, big or small, to it and create a set of female moulds. Detailed things were made in ply or MDF, and the large simple shapes were cut from Isoboard EPS insulation foam, recommended by the guys at CG. I designed the boat and made the 3D model so that everything would be able to be done this way, and it was super quick to pull parts out, create the toolpath and press print. I set up a new dust extraction system to deal with the polystyrene dust, and it works really well. didnt miss a drop.
Heres a photo of the setup, and another after a weekends of successful routing.
The bigger parts took an hour or two to cut, the smaller ones obviously were quicker. I had a couple of small issues cutting the foam where it melted etc, but thats boring so I wont go into it. Thick parts were made in layers 75mm thick, and then guled together with epoxy later. The rough-ish surface (3mm step) sanded back easily and I then sealed it with some epoxy and colloidal silica bog. Then another quick sand, another layer of thinner epoxy/silica, carefully applied with a credit card, and youre done! The moulds all held a good vacuum with no problems, important because you cant envelope bag it as it compresses the foam, and the surface quality was generally within range of high build. Its gotta be the quickest way to make large composite parts.
The MDF/ply bits are now pretty straight forward. Ive learnt that its better to cut them with a much finer stepover (1.2mm or so) so that you almost dont need to sand them. It takes a bit longer on the machine, but saves you lots of stuffing around later. Then one coat of resin and a sand and theyre good to go. The foil strut mould was the last thing I did, and turned out the best.
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