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Old 06-03-2011, 07:51 PM   #886
Cranky Yankee
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Originally Posted by Poolside View Post
I'm sorting out the holding fixture for the potting process. There's a lot of items to hold in place just so. Also, how to pour the epoxy and fill the box without making voids. Pour is the really wrong term here, there's no way to pour it, the gaps are too small. Imagine trying to pour maple syrup down a straw.

I'm working on two different methods. One method is to fixture the board exactly aligned, and inject the epoxy with a large bore syringe. The other is to pre-fill the epoxy by weight into an empty box, then plunge the completed board and wires into it.

The hypodermic method has its advantages, but half the time the epoxy doesn't fill properly under the board and a bubble forms, only to pop out later right as the epoxy is setting. Grrrr. The plunge method also has things going for it, but it's very easy to make a small splash. And at this postage stamp scale, a small splash is a wave. Hang five.

I'm going to try a one half pre-fill, then plunge the board and fixture it, followed by a post-fill to the final level. That seems like the best parts of the two methods.

As you can imagine, a mistake during this step makes a scrap part.

I still have my old vacuum pump used for epoxy potting runs.

Wanna trade for one of the upcoming 1200 can-bus modules?

I'm done with the carbon fiber molding crap.

(yeah, modified dishwashers, flux and DI bottles, those were the days. )
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Old 06-03-2011, 08:39 PM   #887
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I've heated epoxy in advance of using it laminating balsa before. It thinned out real nice, then when the heat set off the epoxy, it hardened up in a hurry! Thinning the epoxy may make getting a even bubble free fill a little easier. But what do I know, I'd end up gluing my eyelid to my cheek or something.

Thanks for your hard work. If you decide to charge more for your phase II product, I for one won't hold it against your!
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Old 06-03-2011, 11:43 PM   #888
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Originally Posted by David_Moen View Post

I've heated epoxy in advance of using it laminating balsa before. It thinned out real nice, then when the heat set off the epoxy, it hardened up in a hurry! Thinning the epoxy may make getting a even bubble free fill a little easier. But what do I know, I'd end up gluing my eyelid to my cheek or something.

Thanks for your hard work. If you decide to charge more for your phase II product, I for one won't hold it against your!
I've once or twice microwaved epoxy for a few seconds to thin it out. This particular mixed epoxy is about the consistency of thick molasses or cool honey. Not too bad for a pour-in-place operation. I would not want to brush it though.

I must settle for the increased viscosity because in this case I need all the working time I can get. The interim steps between mixing, filling, and placing and fixturing the assembly uses up many of the available minutes.

Thanks for the props. When you folks get these goodies on your bikes, it will all have been worth it.


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Old 06-06-2011, 04:19 AM   #889
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Assembly report.

I'm posting this on a netbook from down in the shop. Somehow the wireless router can reach down here now, go figure.

Anyway, I'm crimping and soldering, and waiting for epoxy to cure. Man, 36 hours for a full cure is a long time! A little while ago I rigged up an oven of sorts to try to speed the epoxy curing process. Here's a data point for you... A 75 watt light bulb heats up the inside of a 1ft plastic box to 60/140F! According to the datasheet, at that that temperature the epoxy should cure in 3 hours.


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Old 06-06-2011, 06:17 AM   #890
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You made an easy bake oven!
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Old 06-06-2011, 12:28 PM   #891
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You made an easy bake oven!
Are we going to get cookies with our order?
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Old 06-06-2011, 12:32 PM   #892
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Originally Posted by jbdesigns View Post
You made an easy bake oven!
I am not sure if it is sad or funny but I was thinking the same thing

Here is a photo of him in action (too big for a inline post)

http://4.bp.blogspot.com/_1A-txrEn9M...+bake+will.JPG

R
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Old 06-06-2011, 04:26 PM   #893
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Are we going to get cookies with our order?

Ooh! Ooh! I want oatmeal raisin!
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Old 06-06-2011, 06:08 PM   #894
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Quote:
Originally Posted by jbdesigns View Post

You made an easy bake oven!
Quote:
Originally Posted by rtortore View Post

I am not sure if it is sad or funny but I was thinking the same thing

Here is a photo of him in action (too big for a inline post)
http://4.bp.blogspot.com/_1A-txrEn9M...+bake+will.JPG
Hey, easy fellas! That's not too far from the truth you know!



It looks like this test oven works ok. I just have to scale it up a little. I'm off to the hardware store to get more oven parts.



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Old 06-06-2011, 06:24 PM   #895
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A bigger cardboard box? A higher wattage bulb? Brownie mix?
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Old 06-06-2011, 07:23 PM   #896
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A bigger cardboard box? A higher wattage bulb? Brownie mix?
Ever tried his brownies? ... they have a special someth'n someth'n in there - directly imported from BC

Looking forward to the taste test ... err ... final product.

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Old 06-06-2011, 08:58 PM   #897
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Ever tried his brownies? ... they have a special someth'n someth'n in there - directly imported from BC

Looking forward to the taste test ... err ... final product.
http://cherrypatter.com/wp-content/u...ke-cupcake.jpg



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Old 06-07-2011, 06:58 AM   #898
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I have made custom ovens out out foil back insulated board. With two bulbs and a reostat, I varied the Temp of the oven from low 100s to as high 375 I used it cure baked on finishes on weapons
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Old 06-07-2011, 09:34 AM   #899
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Poolside, if you put a couple of 500W halogen lights in your easy bake epoxy cure oven, do you think we will get this goodie before fall? I've got some splines to strip out on my 04 GSA.
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Old 06-07-2011, 05:21 PM   #900
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Originally Posted by ghostrider1964 View Post

I have made custom ovens out out foil back insulated board. With two bulbs and a reostat, I varied the Temp of the oven from low 100s to as high 375 I used it cure baked on finishes on weapons
Great minds! I was thinking about that material yesterday. With that material I could build the oven to any specific size. Right now I'm using a double thickness of corrugated cardboard. It works ok, but of course it doesn't insulate like the polyiso foil sheets. And would take a lot of 'light bulb' energy to heat a large oven.

I have another oven design in mind for a different application and I'm leaning toward an aerogel sheet product called Spaceloft. (http://www.aerogel.com/products/overview-product.html)


Quote:
Originally Posted by jbdesigns View Post

Poolside, if you put a couple of 500W halogen lights in your easy bake epoxy cure oven, do you think we will get this goodie before fall? I've got some splines to strip out on my 04 GSA.
Got wheelies? Seriously though, I want to help with breaking your bike :-), and the 500W bulbs will certainly speed up the epoxy cure, but the maximum service temp of the vinyl jacket for the wire harness is 80C/176F.



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