I think infusion would be awesome - but the setup cost, experimental failures etc would kill the home builder…
For what? to save 100 grams, and a few hours sanding?
Not worth it for me at the moment, but i’m still doing heaps of research into it.
I’ve got a whole heap of ideas and tricks that I’m trying to find time to do test panels for.
Anyone not interested, stop reading here! this could get long-winded!
The answer lies in removing air from the laminate of course.
Infusion runs at near total vacuum, which it why you can achieve a perfect finish.
When you lam a board, and throw it in a bag, there is nowhere for the air that is caught between the criss-cross of the cloth weave and the bag to go - it stays there, no matter how much vacuum you pull, it can’t get out.
With infusion, the vacuum is pulled before the resin is introduced, so the air is able to escape when the cloth is dry.
Wetness seals air in there…
Perforated release film is the “consumable” approach, and it works well, albeit with a little sanding.
The air can escape through the little holes pretty happily.
But how do you get perf release to bend round the rails of the board without pleating and trapping air, or ugly resin lumps forming in the folds?
Prefabbing flat skins works well like this though.
Pre-sealing the wood helps keep trapped air to a minimum also.
So heres a non-consumable approach for prefabbing flat skins:
Lay down a sheet of polythene, or a polycarb/plexiglass sheet with mold release.
Brush your resin straight on to that, as if you were hot-coating a board, spreading in around to get an even film the whole way along. The resin is the same weight as the cloth your about to use of course.
It will be a thin layer of resin!
Then lay your cloth down on top of the resin, and let the epoxy soak up through the cloth, achieving full wet-out.
This technique means that air will be released upwards and out, the cloth is just sinking, as if you threw it into a swimming pool.
Then, lay your wood on top of that. The veneer can be just taped together on the outer face, in whatever groovy pattern you like.
Put the whole lot under vac.
You can vac in against a flat board (polycarb will work by itself) so that the veneer planks are all flush on the glassed surface, and you can fair out any missmatches in plank thickness on the dry side of the wood.
This can be done really quick and rough, as that grain is not gunna be visible.
The only place you have introduced air to the laminate is between the wood and the cloth, and hopefully it will stay there, or even better, be forced/sucked in to the wood by the vacuum and pressure.
Down between the cloth/resin/polythene interface, there never was any air, so that should come out as perfect as the polythene or polycarbonate surface it is pressed against.
Remove that air thats trapped in the cloth is the important bit, as that is where the whole pin holing problem comes from.
Ok, resin ratios and lay-up technique:
Just less than 1:1 with fully wet out cloth is actually easy to achieve!
The problem is, that when the cloth is that “dry”, there is space between the fibres for air to be trapped, as detailed above.
So then, hot coats, 2 pac, etc are required to fill those voids.
As remarked on in an older thread, I count that towards your resin ratio, so your finished board is actually much worse than 1:1 !
It is good though, because the resin cloth matrix, where all the strength is, has been formed properly, is super tight against the board, not a floating bond, and has as little of that brittle, non flexing resin as possible.
It just has extra goop all around it for waterproofing and cosmetics!
I figured out how to easily wet out and unfold the cloth onto the board, and i don’t have any problems with dry spots, even if the lam is not getting vacced.
What I do is:
Use a shallow baking tray, as big as you can find.
Lay a sheet of polythene down in it.
Cut cloth to the size you want - do this on the board, as if you were glassing a PU/PE, allowing for laps, or whatever, but don’t cut the V’s for the nose and tail.
Just remember roughly how much the cloth over hangs, as this is important.
Weigh the cloth.
Fold it up from one end of the board, and fold it to a size so that it just fits into the baking tray.
The reason to use a really big baking tray, is so there are fewer layers of cloth that the resin has to soak through.
Too few layers though, and it becomes hard to get the small amount of resin to wet it all out - like a hand lam with too little resin.
A baking tray size works great!
When wetting out, pour half the resin on the cloth, push it around for a while, letting it soak in.
Then pick up the cloth and turn it over, so the dryer underside is on top. Use the rest of the resin on this side.
That really helps to get the thing even saturated with so little resin.
Try not to force it in, as your just making air bubbles…
Make sure it’s all wet, and you’ll have no dry spots when you unfold it.
To unfold it onto the board, remember which end you started folding the cloth up from, so you’ll be unrolling it from the other end, and finish where you started. Smooth it down with the squeegee as you go.
The trick is to realise that the weave of the cloth stretches and racks around the place a lot when wet, so it’s easy for the cloth to come out shorter and fatter or longer-thinner than the original cut!
So as your unfolding from one tip of the board, stretch the cloth as required so that it is at roughly the same width as when you cut it, the same lap overhang, or whatever.
Don’t unfold too far ahead of yourself! Get the width right, then unfold more.
Doing this ensures that when you get to the other end of the board, the cloth turns out the right length, not stretched too long or anything.
I use a pair of old resiny scissors to re-cut the laps where necessary, remove any hanging strings, and just generally tidy it up, as you’ll never unfold it perfectly.
Now is the time to cut V’s for nose and tail.
Wrap the laps, and run over it all with the squeege so it’s all tight.
If you do have any visually dry spots, theres always a tiny bit of resin left in the mixing cup you can dab on.
See that resin left in the cup?
Thats how much less than 1:1 you got! weigh it then celebrate with a beer… I think 1 beer for every 2 grams you save is
appropriate.
That was pretty long-winded…
Hope I havn’t bored you all to death, but I find it’s the little technique tricks that make life so much easier!
Kit