Total n00b Duplicating Plastic Computer Case W/ CF

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#1

Hi everyone,

I am planning to do a little computer case modding and one of the plans I have in mind is to replace the ugly beige plastic front cover in a normal atx tower case with a carbon fibre duplicate. Clearly this face cover does not bare any structural load and serves cosmetic purpose only.

After a little research online, I decide to make a female mold. Naturally, my original plastic cover would be the plug of my project. I also plan to make the mold with chopped strand mat. Now here are my questions:

  1. What materials/tools do I absolutely need (at this stage, I am solely focusing on prep the plug and making the mold)?
  2. How hard is it to drill/sew through CF pieces? I will need to make holes for the screws, LEDs, fans, and optical drives when the piece is done.
  3. There are some holes and details on the original plastic cover which I don’t need in my final product. What is the best material to fill them?
  4. There are some texture on the plastic cover (plug), what is my best bet to achieve a class A finish?

Thanks for reading and thanks for your time in advance.

#2

Before I venture a response to the questions you have raised, I sit here looking at the front of my computer and note that there are an number of different surface shapes, many with sharp angles. If your idea is to make a carbon fiber face plate replica, you must know that carbon fiber tends to want to lay flat. Making the mold will be relatively easy, but in making the actual piece with these shapes, I need to ask what you plan is there. I think that a wet lay-up is out of the question. Meaning, just laying the carbon fiber in the mold that you have made and adding resin will probably not work as the carbon fiber will keep popping out of the corners. Before you undertake this project you will probably need to consider either vacuum bagging or vacuum infusion. Have you give any thought to your plan for making the final piece and is this consistent with the amount of effort/time you want to put into the project?

#3

Thank you kyankton for your reply.

This is exactly the kind of advice I need. While it is very easy to gather examples on the net about different peoples’ great projects, it is these small points we newcomers overlooked.

I am willing to take some time to investigate into this project. So please tell me more if you can. Actually, when I post original message, I had vaccum bagging in mind. Thinking that it might me more easily to get the CF into those corners. I am not sure now whether it is still doable by a novice.

I still really want to attempt this project, just need more advice before I take that plunge.

Thanks again for all of your time.

#4

My computer case side view and it is a simpler overlay the sides and top panels:

#5

Hi Werksberg, thanks for showing me your work. It is very nice indeed. However, I planned all along to paint the metal parts. Just wondering if I can replace the plastic part with CF… just like what people normally do with their car hood.

Anyways, does it mean that my idea would be a very difficult to do, from another expert opinion?

Thanks again

#6

Yes, very difficultly as Kyanton mention and with the special attachments required too, I’d look at CF overlaying the face. Saves time and expense too!

#7

I guess it is good to know where my limits are :(. Thanks for all the advice. I think this project is really difficult, as 2 experts agreed it is challenging.

Another potential problem I just discovered was that it could be even more difficult to make the mounting that would tuck nicely back into the metal chassis. I think I need to trash this idea :mad:.

How about my options of overlaying? How should I prep my plastic surface? Should I use less dense cloth so that the CF bends better and fit more tightly to the details :confused:?

HA, this art is really deep and I and starting to get more interested as I read more.

Thanks.

#8

Just use the stock metal side panels (remove and plastic windows ans fans…), paint them black if they are not already, tape off with flash break tape the lip that goes under the other panels, wet lay up 1x layer (or what we do in the class is to use Pre-preg, vacuum bag it and oven cure it) of lite weight CF, you can vacuum bag it or open lay it up and when in a “B” stage…take a hooked blade knife to trim along the steel panel edge.

Let it fully cure and then decided if you want to spray Cystal clear Krylon paint, duratec top coat or craft store clear epoxy bar top coating, but keep the tape there as when the top coating gets gelling, you can still pull and remove the tape to keep that edge clean.