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LW
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Joined: 03 May 2010
Posts: 82
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 Posted: Mon May 03, 2010 6:21 pm Post subject: An affordable instrument pod. |
 #1 |
I made a pod for myself, then decided to make a few more to sell.
It's made using very simple composite techniques. It's a solid foam plug shaped and covered with fiberglass, Kevlar, and carbon fiber.
Using a rotary tool like a Dremel you cut the fiberglass and carve the foam inside to fit your instrument(s). Then it can be painted or left natural. The pod uses 4mm hardware (compatible with the Flytec HG bar mount, not included).
The price is $50 including shipping to the 48 states. Add actual shipping costs for international shipping.
Check out this blog for step by step pictures of how these are being made. Of course feel free to copy these techniques to make your own home made pod, or save yourself hours of messy work and buy one from me. 
http://liftjunkie.blogspot.com/
Last edited by LW on Mon May 03, 2010 7:39 pm; edited 7 times in total |
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LW
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Joined: 03 May 2010
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| Posted: Mon May 03, 2010 6:21 pm Post subject: |
#2 |
1: The first prototype, finished with basic Krylon spray paint.
Last edited by LW on Mon May 03, 2010 6:25 pm; edited 2 times in total |
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LW
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Joined: 03 May 2010
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| Posted: Mon May 03, 2010 6:21 pm Post subject: |
#3 |
2: The state in which the pods will be sold. (production models will have carbon fiber stringers and no black marks on the fabric)
Last edited by LW on Mon May 03, 2010 6:25 pm; edited 2 times in total |
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LW
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Joined: 03 May 2010
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| Posted: Mon May 03, 2010 6:29 pm Post subject: |
#4 |
3: The 3 styles being made in the first batch.
Last edited by LW on Mon May 03, 2010 6:30 pm; edited 1 time in total |
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LW
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Joined: 03 May 2010
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| Posted: Mon May 03, 2010 6:30 pm Post subject: |
#5 |
5 posts so I can post pictures.
Comments and questions welcome. |
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Willmrx
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Joined: 12 Jan 2008
Posts: 1602
Location: Northern Cal
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| Posted: Mon May 03, 2010 9:08 pm Post subject: |
#6 |
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BBJCaptain
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Joined: 21 Jan 2010
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Location: Las Vegas, NV
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| Posted: Mon May 03, 2010 9:56 pm Post subject: |
#7 |
nice work 
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dievhart
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| Posted: Mon May 03, 2010 10:04 pm Post subject: |
#8 |
sweet.....I guess we could just cut a hole in the front for a windspeed indicator? Have you thought of this option?....I use that flytec type....
they look nice...I need to work more and fly less so I can afford more toys...yeah right.
Diev
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feathered1
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Joined: 18 Oct 2007
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Location: New Jersey
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| Posted: Tue May 04, 2010 6:28 am Post subject: |
#9 |
LW,
What kind of foam are you using? I started to make a fiberglass tailfin for my glider and quickly realized that the pink insulation foam from homedepot was NOT the material for the job. The fiberglass resin melted the foam. I eventually got my hands on some foam from aircraft spruce and specialty. The foam I have does not melt when in contact with the resin, but it is so fragile that it can be shaped with a bare hand. Your foam looks to be more durable than mine?? Where did you get yours? What is your core material called? Thanks.
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LW
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Joined: 03 May 2010
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| Posted: Tue May 04, 2010 6:30 am Post subject: |
#10 |
| dievhart wrote: |
sweet.....I guess we could just cut a hole in the front for a windspeed indicator? Have you thought of this option?....I use that flytec type....
they look nice...I need to work more and fly less so I can afford more toys...yeah right.
Diev |
Adding an airspeed probe would be no problem at all. |
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blindrodie
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| Posted: Tue May 04, 2010 6:47 am Post subject: |
#11 |
Very nice setup.
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LW
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Joined: 03 May 2010
Posts: 82
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| Posted: Tue May 04, 2010 7:13 am Post subject: |
#12 |
| feathered1 wrote: |
LW,
What kind of foam are you using? I started to make a fiberglass tailfin for my glider and quickly realized that the pink insulation foam from homedepot was NOT the material for the job. The fiberglass resin melted the foam. I eventually got my hands on some foam from aircraft spruce and specialty. The foam I have does not melt when in contact with the resin, but it is so fragile that it can be shaped with a bare hand. Your foam looks to be more durable than mine?? Where did you get yours? What is your core material called? Thanks. |
I use the Dow blue foam sold at most hardware stores for insulation. In the construction world it is called 'foamboard'. It is very similar to the pink foam you used, which I have also used before (other projects) with excellent results.
Owens Corning foam is pink and is called Foamular XXX. Formula 150 is 15psi, Formula 250 is 25psi, etc. Dow foam is blue and has different names, like Score Board (15psi), Square Edge (25psi), HiLoad 60 (60psi). Comparably rated foams from each company are very similar in every way, the difference in color only represents the trademark color of the company.
If you are building stressed skinned structures that rely on the foam to provide sheer or compression strength then these details matter. Higher psi greatly increases strength to weight ratio. For building these pods the foam is only there to provide shape during layup, so any of these foams will work.
To me it sounds like your problem was your resin. What were you using? Generally a low viscosity laminating epoxy is best, West Systems, Pro Set and Z-poxy are the ones I have good experience with. Many other resins and paints will destroy all of these types of foam. |
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feathered1
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Joined: 18 Oct 2007
Posts: 158
Location: New Jersey
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| Posted: Tue May 04, 2010 7:31 am Post subject: |
#13 |
aha! I was using all purpose fiberglass resin. again..home depot variety. I think the foam I ended up using was a polyurethane foam. And, if I'm not mistaken, the insulating foam is a polystyrene. So epoxy does not melt polystyrene? Good to know! Thanks.
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LW
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| Posted: Tue May 04, 2010 8:57 am Post subject: |
#14 |
| feathered1 wrote: |
| I was using all purpose fiberglass resin. again..home depot variety. |
"All Purpose Fiberglass Resin" sounds like the Polyester resin from Bondo sold in hardware stores. I think that was your problem. |
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bsquare
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Location: Memphis, TN
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| Posted: Thu May 06, 2010 5:16 am Post subject: |
#15 |
LW - check your pm's man. I would like to buy one of these things.
B^2
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peanuts
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Joined: 08 Jul 2008
Posts: 1880
Location: virginia
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| Posted: Thu May 06, 2010 5:24 am Post subject: |
#16 |
| as to the resin melting the styrofoam, in the past i had excellent results with any foam or glass. i simply painted the foam with "Elmers" wood glue and allowed this to dry. it protected the foam just fine thank you, and sticks layers of foam together if you need larger or odd shapes. |
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remmoore
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Joined: 24 Jul 2008
Posts: 1311
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| Posted: Thu May 06, 2010 9:52 am Post subject: |
#17 |
An alternative to messing with carbon or fiberglass is to use a closed-cell, mini-cell, polyethelene foam. Me and a buddy have built two this way:
http://ozreport.com/1202158745
The process for carving and shaping the foam is very similar, but instead of laying on carbon/fiberglass over the foam we just sprayed it with Plastidip from Home Depot. Cheap and easy.
RM |
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Tigouille
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Joined: 28 Mar 2010
Posts: 271
Location: france limoges
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| Posted: Fri May 07, 2010 2:39 am Post subject: |
#18 |
you win with spraying!
not too heavy?
I have never seen this rubber you can spray in France, but i am not a DIY guy. |
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LW
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Joined: 03 May 2010
Posts: 82
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| Posted: Fri May 07, 2010 6:20 am Post subject: |
#19 |
| remmoore wrote: |
| An alternative to messing with carbon or fiberglass is to use a closed-cell, mini-cell, polyethelene foam. |
Remmore I saw your pods when I was researching different pods. They look very cool but I wanted the weight and strength you can only achieve with composites. I really don't find the fiberglass difficult to deal with either.
Bssquare, Check you pm.
The first batch of these will be ready next week.
Last edited by LW on Fri May 07, 2010 10:21 am; edited 1 time in total |
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remmoore
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Joined: 24 Jul 2008
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| Posted: Fri May 07, 2010 7:08 am Post subject: |
#20 |
| LW wrote: |
| remmoore wrote: |
| An alternative to messing with carbon or fiberglass is to use a closed-cell, mini-cell, polyethelene foam. |
Remmore I saw your pods when I was researching different pods. They look very cool but I wanted the weight and strength you can only achieve with composites. |
LW,
You've got a nice model there - great job.
A reply to your comment above: My foam pod seems to be the same weight as the manufactured carbon pods available. Also, strength is not an issue, because the foam flexes instead of resisting impact forces, plus protects the instruments in a padded surrounding.
I'm certainly not knocking your skills with carbon or fiberglass. I simple don't have such skills, and found a nice alternative.
RM |
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