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Planning Project: OSIDIAS (SFF taken to the extreme)

Gzero

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craigbru

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Make sure you keep the pics coming thick and fast (and shiny too since it's stiff competition usually over at b-t), I'll even put a vote in for ya since I'm loving it :D
Thanks! I appreciate the support. I won't have an update until a little later this week though. I've got a new deadline on my Hutch project, and need to get that finished up.

Lol, thanks bro!
 

craigbru

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Although Project Hutch has been getting most of my time lately, I was able to get a little work done on OSIDIAS while waiting for some JB Weld to dry... I picked up on the continuation of the molds for the interior assembly. When I last updated, I had the inner mold completed. Now it was a matter of laying out and cutting the exterior. What you see here is another 1'x4' piece of aluminum sheet.



After cutting...



Time to get this thing bent!











Now, to get one of the inside bends done, I had to switch to my 18" brake.



With all of the bends done, it was time to see how they fit together. I slipped the outer mold over the inner, and all was well! I've got about 2mm between them. That should allow for about 6 layers of carbon fiber.



Since I knew the molds were going to work, it was time to reinforce the inner mold against flexing. All I needed was a piece of 2x4 cut down to 8cm in width. The board was aligned and epoxied in place. Final measurements indicate that I got the perfect alignment I was hoping for. The back is perfectly parallel top and bottom, and I won't need to make adjustments of any kind.



Up next I've got to add a few pieces of angled aluminum for mounting tabs, and I'm ready to wax and lay down the fiber!
 
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do you mind me stealing you skills :laugh:

oh yeah and btw, are you the one who helped with the NZXT Phantom=?
 

Chicken Patty

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WOW, nice job on th bending dude. :respect:
 

craigbru

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do you mind me stealing you skills :laugh:

oh yeah and btw, are you the one who helped with the NZXT Phantom=?
Lol, no problem man. Steal away! :laugh:

Yes, I worked on the chassis design with NZXT on the Phantom. It's their first custom chassis, and a sign of good things to come. Some things I wanted weren't able to be implemented due to budget or patent issues, but it's a solid foundation. :D

WOW, nice job on th bending dude. :respect:
Thanks CP! We'll have fiber soon!
 

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Looking forward to it :toast:
 
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Baby's got the bends :D
 
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Lol, no problem man. Steal away! :laugh:

Yes, I worked on the chassis design with NZXT on the Phantom. It's their first custom chassis, and a sign of good things to come. Some things I wanted weren't able to be implemented due to budget or patent issues, but it's a solid foundation. :D
damn, im in love with that case, its almost perfect imo, might get one next month :D

and keep up the good work, we needz MOAR Pr0n :rockout:
 

craigbru

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Looking forward to it :toast:
Right now it looks like I'll have time either later this weekend or the first part of next week. I've got a mini vacation starting tonight. :D

Baby's got the bends :D
Lol, nice.

damn, im in love with that case, its almost perfect imo, might get one next month :D

and keep up the good work, we needz MOAR Pr0n :rockout:
Thanks man. We really tried to bring something nice, yet affordable to the market. We actually planned the case out in early 2009. There were some manufacturing delays that pushed it back. Had it come out when planned, it's specs would have been even better compared to the competition at the time.
 

craigbru

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Update time! I actually livestreamed the fiber going down, although it was a huge pain. For some reason I thought it was a good idea to skip taping the edges of the fiber. Needless to say those stray fibers soon became a problem as the layers went down. I managed to keep them out of the way, and got 5 layers on before I ran out of resin. That means I'm a layer short of what I wanted to be. Although looking at the finished assembly, it's likely thick enough, but I'm going to give it one more anyway. I had a little trouble sliding the outer mold in place. The resin kept sticking to the mold and pulling it down with it. Doh, why didn't I wrap plastic around it before the mold?! That would have taken care of the problem, and I'd be done. As it is, now I've got to sand and add the last layer anyway. Mostly for cosmetic reasons mind you. The outer mold caused some wavy weaves because of the sticky resin... and I just can't have that. I'm out of resin though, and will have to order more before continuing.

Well, enough of that. On to the pics! Here I'm using a template to cut out the layers of CF.



Obviously I couldn't take pics while wrapping, but here is the mold all clamped up.



Now it was time to see if that mold wax release was going to do it's job. I had a total of 3 layers on, so I was pretty confident. Success! The outer mold released without an issue. Here you can see the interior assembly in it's freshly released state. There are a few spots that didn't get completely 'covered' with resin, but it's hardly an issue. There was complete saturation and it's damn solid!



Finally, I took the dremel and cut off most of the excess fiber. You can see the interior mold is still in place. There's a good reason for that. It is cut to the exact dimensions that the assembly needs to be. During the final cut down, I'll use the interior mold as a guide to make sure everything is cut correctly. Without it, I don't think measuring out where I needed to cut would have been so fun...





At this point I've got to get some more resin ordered. In the meantime I'll sand down and prep the interior for the last layer of CF. Then I can start making holes in it for all the components and wiring. Woohoo!
 
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hell yeah :D its getting freaking awzumepicness :D

love all that CF :love: lol
 
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i have no doubt about that :D
 
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Phenominal work Craigbru. :toast:

Can't wait to see more of your innovations and creativity :respect: