cfbb's Photobucket Carbon Tiller progress album media

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cfbb — Tue, 10 Feb 2009 06:47:16 MST

cfbb posted a photo

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Fall back to Plan B ........

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cfbb — Tue, 10 Feb 2009 06:45:35 MST

cfbb posted a photo

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Unfortunately, it's also the LAST part from that mold!!

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cfbb — Tue, 10 Feb 2009 06:43:15 MST

cfbb posted a photo

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Well, the bladder molded part doesn't look too bad. At least, not too bad for the firs part from the mold.

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cfbb — Tue, 10 Feb 2009 06:41:33 MST

cfbb posted a photo

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Broke the mold!!

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cfbb — Thu, 5 Feb 2009 17:04:52 MST

cfbb posted a photo

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Tiller plug - left half & right half. Made of MDF, sealed with lacquer, primered and sanded several times, gloss coat painted, waxed and buffed three times.

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cfbb — Thu, 5 Feb 2009 17:04:46 MST

cfbb posted a photo

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Left half screwed down to parting plane board

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cfbb — Thu, 5 Feb 2009 17:04:39 MST

cfbb posted a photo

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Same process for the handle bars

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cfbb — Thu, 5 Feb 2009 17:04:33 MST

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Sides added, waxed and buffed three times, sprayed and buffed three times with PTFE release

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cfbb — Thu, 5 Feb 2009 17:04:21 MST

cfbb posted a photo

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After the urethane cures, pop off the sides and bottom ( parting plane) of the casting mold

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cfbb — Thu, 5 Feb 2009 17:04:14 MST

cfbb posted a photo

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Polyurethane/steel liquid poured in to create first cast

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cfbb — Thu, 5 Feb 2009 17:04:08 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:04:01 MST

cfbb posted a photo

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You now have a block of plastic steel with one half of the tiller plug cast in. The second half plug is glued on to the first half plug. A series of locator dimples are machined in to the surface of the plastic. The exposed plug and the surface of the mold and the sides are put back on. Everything is again waxed, buffed, PTFE release sprayed, buffed. The second half is is poured.

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cfbb — Thu, 5 Feb 2009 17:03:54 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:03:47 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:03:40 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:03:34 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:03:27 MST

cfbb posted a photo

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cfbb — Thu, 5 Feb 2009 17:03:21 MST

cfbb posted a photo

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After the second half cures, the sides are poped off

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cfbb — Thu, 5 Feb 2009 17:03:14 MST

cfbb posted a photo

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Top half and bottom half. You can see the parting line

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cfbb — Thu, 5 Feb 2009 17:03:07 MST

cfbb posted a photo

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Gently insert wedges and pry the two mold halves apart.

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cfbb — Thu, 5 Feb 2009 17:03:00 MST

cfbb posted a photo

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Voila! A half mold (empty) and the other half mold with the plugs still in.