Saturday, January 12, 2013

Two Oops!!

I made a change to the floor of the Borealis V3.  My V3 has an occasional squeak I haven't been able to track down.  Brock thinks he found the source so I ended up adding some more clearance around the frame.  The Sprint has a couple of welded on bits to better manage the cable housings that weren't on previous models.  There is some clearance now but it is not a lot.  Below you can see the cut outs in the mould with chunks of the modified plug in place. I will gel coat the areas then laminate some material over the gel coat.  Once that is hard remove the plugs, sand and then polish. The sanding is a bit tedious but lots less work than building a whole new mould.
The other oops has to do with the rain gutter in the Milan.  I made the second side which was a bit different in shape to the first side.  I ended up liking the second shape better so I am now changing the first one.  Same process as above but a lot smaller mould.

The beige coloured material in the cut out is the change in the shape.  I straightened out the shape so it more closely matches the shape of the hatch opening.  Not a lot of change but right and left sides were different enough to bug me.  
The Milan has been sitting outside in the rain for a few days and the rain gutters work as planned.  I did end up adding some drain holes in the floor so any other water that gets in can drain away.

Tuesday, January 1, 2013

Glueing the Rain Gutter In

The gutter being glued in.  I had to make some special blocks to clamp it in place.  Just barely had enough spring clamps to do the job. I will most likely have to get more so I can glue both sides in at once.  The adhesive I use takes a few hours to set.   Here's what it looks like once the clamps are removed and the drain tube installed.

Closeup of the drain tube.  A bit of silicone seals it to the gutter and holds it in place on the side of the shell.  I shape the top of the tube with heat to fit the inside of the gutter and prevent it from pulling out of the gutter.