Trying to make a gauge holder-Need suggestions

General Composites Discussions Composites Talk
#1

Here is what I am trying to do:

I know it seems easy but i have been struggling with cutting the 2" dia holes perfectly.

Here’s what Im thinking now. Use some 1/2 inch thick aluminum plate cut to the final size.
Drill-bore the 2" dia holes in the plate.

Do a wet lay up of my carbon fiber over the aluminum plate. Use a dremel tool with the sanding wheel and trace the bore. This way my aluminum plate acts as a template.

What do you think?
How would you make this part?
What is an easier way to make this part?

I have access to a manual machine shop and lots of saws, routers and more

IDEALLY: I would like to just use some balsa wood or some 1/8th thick aluminum plate with the holes bored into it and just do a wet lay up onto the final core piece, and do the same router technique ont he final piece. This would avoid gluing things twice.

#2

Make a panel, have it cut with a waterjet. Easy.

#3

Use a single tooth carbide hole saw. Start drilling on the front, but not all the way through. Flip it over and finish drilling from the back. Use an exacto knife to clean the edges if needed.

#4

there are instructions available on the net for making a router template to cut perfect circles. basically involves drilling a small hole in the middle of the pieces and using the template from there to cut a perfect circle. Search “circle router jig” or something along those lines, someone on here may be able to better direct you as well.

#5

http://www.synapsemotorsport.com/Library/SynapseCFone.pdf

here you go heres a tutorial on how to do exactly what your trying to do.

#6

These are all similar techniques as to what I was thinking. Although, seeing thsoe pictures helps answer some of my questions.

I appreciate the pointers. Ill be ordering some carbon hybrid cloth today to start this small project.

Unfortunately I dont have time to lay any parts up for two weeks, but I want to be ready to rock and roll once I have the time