Step 0: Problem
This week I built a composite duct to replace the kink prone dust
collection hose on the shop bot. Hopefully this will cause the
dust collection system to get clogged less often.
Step 1: Form
First, I built a laser cut cardboard skeleton for the mold.
Step 2: Shrink wrap
Next, I tried to shrink wrap the carboard skeleton with the boat
wrap. I used the double sided carpet tape to adhere the wrap to
itself. Unfortunately, the surface formed by the wrap after heat
shrinking was very wavy.
Step 3: Tape wrap
To get a better surface, I removed the boat wrap and wrapped the
form with tape.
Step 4: Lay up
I used strips of linen cloth and epoxy resin for the lay up.
The thickness ranges from two to three plies.
After the epoxy cured, I filled the duct with water and then
removed the soggy tape and cardboard. This worked pretty well.
Then, a quick trim on the bandsaw cleaned up the edges nicely.
Over and out.