these things are such a pain in the ass to make… for some odd reason every other one I made stuck to the mold, was full of air bubbles, and just turned out like utter crap… which meant resurfacing the mold, etc… anyway, they aren’t quite finished… need to actually attach the horns to the flange and do a little finishing work on 'em
Sweet… 
Did you use a two piece mold with a inflatible bladder to push the cf tubing to the outside…
that turned out really nice.
what are you using between that and the itbs to seal them… i know that there is that lip on them (assuming they are cbr itbs)
I actually made a male mold on the lathe, casted it in instacast, and layed up sleeves from aerosleeves on it… worked pretty well…
the cbr itbs come with a nice rubber gasket stock
cool beans
thanks
I like it.
Very nice job?
I have a few questions.
Is there supposed to be some formula for tuning the horns once they are made? I mean for tuning the length of the horns, or am I being misinformed?
I actually made a male mold on the lathe, casted it in instacast, and layed up sleeves from aerosleeves on it… worked pretty well…
the cbr itbs come with a nice rubber gasket stock[/quote]
What is insta cast?
Did you make the male mold of insta cast and turn it up or did you make a female off the lathe turned male? I am a little lost. That was my other question>
instacast is a two part epoxy casting resin…
I made a plug on the lathe out of highdensity foam, then vacuum formed a female mold off of it(vacuum form heats up a piece of polystyrene plastic, drapes it over the male plug, then uses vacuum to suck it tight while it cools off an hardens… then I removed the foam male, and poured the instacast into the mold… when this set, I removed it… the purpose of doing this is it’s A LOT easier to surface a solid cast piece than a fragile foam one… there’s no way I could have used the foam piece as a male plug for laying up carbon anyway… it wouldn’t have held up through multiple pieces
I have my own vauum form press too. I was wondering if you expanded your foam model before vacuum forming the polystyrene over it?
Did you have any webbing issues on the male model?
It looks like it would have webbed near the base unless you added some depth to the model.
Good idea, by the way.
I use a product called re-pro for instant casts. it is a urethane and has such a minute amount of shrink that it i aalmost immeasurable. it sets up for demolding in half an dhour and routers and sands beautifully.
Pattern makers and modelmakers used to buy it by the 5 gallon drums.
Saxman, don’t get mad at me but…a vacuum forming process does not suck the PS to the mold. It removes the air pressure that is all around us and with the negative pressure, the positive pressure pushes the PS sheet down to the mold…
Sorry, I can’t help myself… 
Oh shut up JM!
L.O.L.
You are right, but everytime I explain it to someone I tell them the vacuum sucks it down to the plug, or model.
L.O.L.
Jeez…Get a grip!..L.O.L.
It took me too many years to get the correct point of it but when it hit me it was like a big crap with hemoroids…! :shock: :lol:
I added a couple inches of material to the base of the plug to allow for webbing… it was rather minimal and a quick hit with the dremel took care of it
re-pro sounds like basically the same thing(just read up on instacast, seems it is urethane, not epoxy based)
and yes, I know that technically it’s the positive pressure pushing the styrene onto the plug, but it’s so much simpler to just think of it as being sucked on… much easier to convey that way as well.
I think some people that didn’t know what’s going on would get confused by me saying “well, the positive air pressure pushes it onto the plug”