Build thread: Fiberglass fenders

[srimes]

Very nice! :cheers:

Carbon isn't very flexy. Kevlar's great though.

 

[jdbwrx]

Where did you get your solids model of the XJ? I just finished building a large laser 3D digitizer and I am getting ready to digitize my XJ for use in SolidWorks.

Nice work. It's good to find other fabricators that use technology.

Thanks Tom.

I didn't have a solid model of the XJ. The .3ds model was just faces. The stuff I drew in Rhino was also faces. I exported out of Rhino as an .stl and into Magics which is an .stl editing program. Magics has an awesome command called "surface to solids." I was able to boolean the parts together and smooth out the intersections in that program. That is where the solid part came from that I could machine from.

We use Magics to prep most of our 3d printing/rapid prototyping files. I would love to be able to work with Solidworks, but between the cost and the fact that we don't do a ton of industrial design type parts, we haven't come up with a need for it in our workflow. Some of our clients draw in solidworks and it sure is nice getting good files.

I would have LOVED a 3d scan of the fenders. It would have made building the plug a ton faster. Let me know when you get it up and running, as I'd love to go over some of it with you.

 

[Oil Town XJ]

Where did you get your solids model of the XJ? I just finished building a large laser 3D digitizer and I am getting ready to digitize my XJ for use in SolidWorks.

Nice work. It's good to find other fabricators that use technology.

I would love that file after your done!

 

[jeeperjohn]

Very nice! :cheers:




Carbon isn't very flexy. Kevlar's great though.

This is why I suggested a hybrid material. A pure kevlar material would not be rigid enough and a pure carbon material would be too rigid. A hybrid material can be woven in such a way as to have the right amount of both properties for your needs.

 

[Oil Town XJ]

This is why I suggested a hybrid material. A pure kevlar material would not be rigid enough and a pure carbon material would be too rigid. A hybrid material can be woven in such a way as to have the right amount of both properties for your needs.

X2 But if your not going to vacuum bag it, just stick with E-glass.

 

[O-Gauge Steamer]

Just an FYI,

To cure standard pre-preg (FR-4, G10 etc) takes 350 degrees for an hour. If you are running multiple layers, it will need to be under pressure. Vacuum bag in an autoclave will work. Pull the vacuum in the bag and then pressurize the autoclave prior to adding the heat. Other wise, you risk delamination as the material will not bond properly. Used to be a Lamination Engineer in the Printed Circuit world. Multilayer boards are glued together with pre-preg...

 

[afroengineer]

Where did you get your solids model of the XJ? I just finished building a large laser 3D digitizer and I am getting ready to digitize my XJ for use in SolidWorks.

Nice work. It's good to find other fabricators that use technology.

I would love/pay for a copy of that file also!

 

[jdbwrx]

Finally managed to get these finished up. Overall, very happy. Had a little trouble with the paint this weekend, so ended up painting them completely with the Rustoleum hammered, instead of the black/white combo I had originally wanted. I can always add that later I guess.

Few pics after 1st prime and pinhole filling (ready for primer coat #2):

Done for now...

 

[Prosonic]

Do want. If you can keep the price right, you should definitely think about making a production run.

 

[Gaius]

Damn, nice work.

You think they'll hold up to some rock/tree smackage?

 

[r33pwrd]

Damn, nice work.

You think they'll hold up to some rock/tree smackage?

I cant see them holding up to trees... :dunno:

 

[jdbwrx]

Damn, nice work.

You think they'll hold up to some rock/tree smackage?

Guess we're gonna find out!

 

[r33pwrd]

Guess we're gonna find out!

That would be cool as hell if they did!

 

[s14unimog]

damn, you're so lucky to have access to a 5-axis mill like that. Do you work at a cart shop or something? I know those puppies aren't cheap. Kick-ass fender btw, forgot to add that.

 

[mutt550]

Nice!!! Would love to have a set of those!! Price please? You really should look into selling these. Keep them priced right and you'll have a bunch of orders. Nice work either way!!!:thumbup:

 

[Talyn]

Nice. I wish the router at my work could do that.

 

[jdbwrx]

damn, you're so lucky to have access to a 5-axis mill like that. Do you work at a cart shop or something? I know those puppies aren't cheap. Kick-ass fender btw, forgot to add that.

Unfortunately it's only a 3 axis mill, but I would love to get my hands on a 5-axis. I work for a company that does architectural models. The mill is primarily used for making terrain forms.


Not sure if I wanna try and sell these. It was kind of a pain in the ass (a good learning experience though). I don't think my tolerances are tight enough for the general public. I had to work and "massage" things a bit. I'd want them so people could bolt on and go, and I'm not quite there.

Now if somebody had a 3D scan of a stock fender, that would be another story. I think I could make a real go of it then.

Thanks for all of the positive feedback.

 

[Cody90XJ]

Awesome fenders but, I gotta ask. Wheres the rest of your license plate?

 

[jdbwrx]

Awesome fenders but, I gotta ask. Wheres the rest of your license plate?

Ha ha. I had an extra O2 sensor bung in my exhaust system that I wasn't using and just had a threaded plug in it. On one trip the plug vibrated itself loose and fell out and I didn't have a spare. So I cut a piece the corner of the aluminum license plate off and used an extra hose clamp to cover over the hole until I got home.

 

[ArmyGraham]

You gonna make matching rears?