The two gussets with the holes in them are the ones in question. Does anyone have any idea how to mold them? Any help would be appreciated! Thanks
I would use aquacore, as I already made some time ago.
Otherwise, if their bottom side is hollow, you can mould a silicone mandrel to pull away after curing.
I would do them as a simple 2-piece mould, drill the hole out after curing.
How thin/thick are they, what are the approximate dimensions and do you need them solid?
Core matieral. Fill in area around where the bolts go, else you will crush the core. or use solid laminate at the top. Drill.
Or bond in metal tube, and use that to support the bolting.
Here is the thickness. I can drill the hole after molding but not sure how to mold it and get the part to come out looking nice. Silicone maybe?
Ah…tabs are solid, and the rest is hollow. I don’t see how, except a multi-part mold (where layup will be VERY VERY hard to do), is to just use a shaped bladder, foam core, or something else to get the shape. Now, those tabs will be problems if you want to make this in one shot. Those will need compression molding halves of some sort, that clamp the material, compress, and keep the shape, along with keeping it aligned with the part.
Secondary bonding is a choice of course…
Would this work? What problems should I be looking for?
What about molding those two pieces separately and then glue together
luxury,
would the glue hold over 300lbs without ripping o breaking?
300lbs… should be cake. Bonding adhesive is extremely strong. There are many to choose from, some rigid some flexible.
We routinely bond airplanes together with it.
here’s the tech data sheet for loctite 9394… just one I picked because I’ve used it, Henkel has many structural adhesives.
Though bonding does add one more step and you have to be very through to ensure a good bond, but not rocket science.
Sam,
Thanks a million! You are a huge help with my learning of composites! Really appreciate your help and knowledge!!!