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Old 08-20-2003, 09:47 PM   #1 (permalink)
Insane
 
Location: San Diego, CA
Fiberglass Resin

======= BEGIN history of project =======
I am building a watercooling system for my computer. I got a case, hacked it up and mounted a 12 1/2" x 6 1/2" x 2 1/4" radiator on the top (this thing is a friggin behemoth) with barbs I attached with marine goop. I mounted the pump upside down in the back of the case, with a resivour below it (I know, not the best place for bleeding) and I got my tubing all cut up and clamped on everywhere. The only thing I have to do now is mount the fans on the radiator. That is where the fiberglass resin comes in.
======= END history of project =======

What I want to do is make a mold that will cover the outside of the radiator and then taper to a 10" x 5" rectangle where the 2 120mm fans will be mounted.

The thing is, I am not sure which way I should make the mold for the resin. Either I can make plexiglass rectangles for the top and bottom, raise one up with a piece of wood or something and then cover the whole thing in nylon stockings. Then apply the resin to the nylon and let it do it's stuff. Then I will have the shape I want, and the top should be strong enough to drill two holes in for the fans and then mount them. The thing is I don't have any used nylon stockings and I have heard that you are not supposed to use new ones for some reason.

The second way I had to make a mold was to cut styrofoam to make the frame of what I want (probably using plexiglass for strength anyways) and then apply the resin to that. Then I could use --I forget what chemical-- and dissolve the styrofoam and leave the hardened resin in tact.

Which one of these methods would you suggest, and for that method, should I dip the whole mold into the resin, or kind of paint it on with something?

Thanks.
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Old 08-21-2003, 07:40 AM   #2 (permalink)
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Location: Wisconsin, USA
Just get a fiberglass repair kit from the auto dept. at the local store. Should be plenty of glass for your needs without costing a lot. Hose is not going to be strong enough unless I misunderstand and you mean for the plexiglass and/or wood to remain? In that case, you don't need the resin in the first place.

I think the simplest way for the resin/cloth route might be to create a form and wrap it in saran wrap. This should allow you to remove the form and the wrap after it cures.

Personaly, I'd just make the shape with some aluminum or steel flashing and skip the resin alltogether. You could also use 1/8" aircraft plywood from a hobby store.
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Old 08-21-2003, 08:50 AM   #3 (permalink)
Insane
 
Location: San Diego, CA
That saran wrap was the thing I was looking for. I have never worked with resin, and I wasn't sure on what it would stick to. I will try and make the mold today and see if I can get it staying on the saran wrap.

Here is the basic idea of what I am going to do (except mine will have to be much larger and I have no mounting brackets on my radiator so I am gonig to have to find another way to mount it.


http://www.procooling.com/articles/h...te_air_du1.php
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Last edited by Raw Kuts; 08-21-2003 at 09:26 AM..
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Old 08-21-2003, 11:23 AM   #4 (permalink)
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You need the stockings or fiberglass cloth, or some matrix like that for the resin to go on to. The resin is crap without the stockings or glass to give it tensile strength. The matrix is like steel bars in reinforced concrete - without it the shroud will be brittle and weak. I think the method they showed in the article is ingenious. I would just take some wire coathanger to hold the fan on to the radiator, maybe 4-6 inches away from each other. If you just had one piec of coat hanger going from each corner to each corner it would hold everything where you want it to be. You could use whatever other smaller pieces of wire or string, etc. for X bracing if it wont stay steady. Then, just go to the drugstore and buy 2 or 3 sets of cheap pantyhose. Wrap then around, between the fan and the radiator. You can wrap them right onto the frame of each component. If there is any part of each component that you don't want to get attached or resin on then put wax or plastic packing tape on it. You are depending on the resin going through the hose and sticking to the frames of the components. This, and the mechanical bond should hold fine. I would want at least 4 layers thick of nylon material. the resin is applied sparingly from the outside so that it soaks it all. It acts as the glue that bonds the whole mess together. It isn't "fiberglass resin" it is polyester resin, fyi.
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Old 08-22-2003, 07:08 AM   #5 (permalink)
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Location: Wisconsin, USA
I have to admit I hadn't considered that you might be using multiple layers of stocking, but it still doesn't seem right. Must work though! I like the way he created the form.

Yes, it's properly called polyester resin. It's not made of fiberglass after all. However, the other name was more likely to not generate more questions.
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Old 08-22-2003, 09:19 AM   #6 (permalink)
Insane
 
Location: San Diego, CA
This is the stuff I got: http://www.partsamerica.com/PartDeta...egoryCode=3269

It says polyester in small letters on the top, and then below it Fiberglass Resin in big letters. Hope this is the right stuff.

I got the mold made out of two fiberglass pieces I cut, and then I used a coat hanger at the very base and then I streched the nylon (god, that was worse than buying condoms) horizontal and anchored it. I have wax paper a few inches from the base so I get "feet" so I can have somewhere to screw into the top of the case.
I will probably do the resin tommorow, I don't wanna leave it outside unguarded or I'll have masses of suicidal bugs drying with it.
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