Newbie needs to know where to begin...

General Composites Discussions Composites Talk
#1

I have several projects that I want to do in composites, the easiest is probably a 2’X2’X1’ box I would like to make out of carbon fiber. I have a basic box of that size made out of a plastic material with seams and other ugliness, and I am not sure if I can even use it for a form.

The box will have a door on one of the 1’X2’ sides and the rest will be closed.

What I can’t figure out is where to begin with this- I would like to make the box out of one solid piece and then cut and fit the door, but how do I create a mold for that? Is making it one piece even feasible? If I could make a 5 sided box that might work.

Anyway, I can’t find any complete tutorials in the forums and a lot of the links I see are deadends.

Any help would be greatly appreciated!

#2

What is the final use of this BOX?
Speakers?
Boom box?
Junk box?
X Box or Playstation with DVD and screen?

Where will this box be used too?
Does it have to have square / parellel sides or curves?

#3

I knew I shoulda just put that in! LOL

This box will be a giant hood for a hawk. What will happen is a perch will be installed in it for the bird to sit on and then the door is closed so that the bird is in the dark where it will be safe and calm.

The box will be used both indoors and out.

The sides would be best if they were parallel and flat, but the corners of the box can (and I would like them to) be rounded.

I took a picture of it to give you a better idea:

I could build a mockup of the box to make a mold from, but I need some advice on that point. I am hoping to make this using carbon fiber and it won’t be the only one I will make; there will be at least two of them made, maybe more.

I also plan to add other features to it such as ventilation channels that don’t let light in, etc. but I will be able to figure those details out as I learn from this first project.

I hope this info helps in your answer!

Thanks!

#4

I’d never put a live animal in a black colored box, unless you wanted 'em cooked. The surface temps for carbon fiber in the sun can easily reach 180 deg F. in a short time. Your original box is white in color for a reason.

Just my opinion & everybody’s got one. - Bob

#5

They aren’t left outside in the box for any length of time and NEVER in the sun regardless of the box color.

The time of year they spend the most time in the box is in the winter time when heat isn’t a factor anyway. Otherwise they are only in it for transport from one place to the next.