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My 200mm C/F Newt Project

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#1 paul11

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Posted 11 October 2009 - 09:43 AM

Hi all I thought I would post a thread on how I made my 200mm F5.475 Carbon Fibre Newt. First of all I would like to say thank you to John Carruthers for all the help he gave me with the mirror, without his help I would never of finished it. The first image just shows the mandrel with 6 coats of release agent on it. I did split the mandrel so I could remove the cardboard tube in one piece but this didn’t work very well and the cardboard tube came out in many pieces.

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#2 paul11

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Posted 11 October 2009 - 09:49 AM

In this image I have coated the mandrel in Epoxy Resin and put on the first layer of C/F and wrapped it in peel ply.

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#3 paul11

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Posted 11 October 2009 - 09:51 AM

The next day I removed the PP

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#4 paul11

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Posted 11 October 2009 - 09:56 AM

Then I put on a 3mm layer of Coremat that I fully saturated with E/P first.

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#5 paul11

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Posted 11 October 2009 - 10:05 AM

These two images show a layer of C/F going over the Coremat, if you start of nice and straight that’s how you will finish up.

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#6 paul11

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Posted 11 October 2009 - 10:06 AM

Image 2

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#7 Wes James

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Posted 11 October 2009 - 10:10 AM

Looking very good! What is Peel Ply???

#8 paul11

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Posted 11 October 2009 - 10:16 AM

Then I applied one more layer of C/F and three more coats of E/P to make sure the C/F was well under the surface. Then it was outside to cut the surface down until it was even and finish it with 1200 wet n dry.

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#9 paul11

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Posted 11 October 2009 - 10:26 AM

When I was happy with the look of the C/F it was back into the workshop to cut the tube to length (1200mm). I set the depth on the Router, set the fence and ran it around the tube.

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#10 paul11

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Posted 11 October 2009 - 10:27 AM

And 2

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#11 paul11

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Posted 11 October 2009 - 10:58 AM

Then I applied a single coat of Blakes 2 component high gloss clear polyurethane varnish all I have to do now is to finish it off with a burnishing cream.

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#12 paul11

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Posted 11 October 2009 - 11:08 AM

Then I made the lid for the tube, I used a piece of hardboard for the base and cardboard for the walls and put on a single layer of C/F and finished it the same as the tube. To remove the cardboard and hardboard from the C/F I just put it in a bucket of water for a few hours.

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#13 paul11

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Posted 11 October 2009 - 11:09 AM

lid

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#14 paul11

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Posted 11 October 2009 - 11:15 AM

Lid on tube

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#15 paul11

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Posted 11 October 2009 - 11:53 AM

Looking very good! What is Peel Ply???

Hi Wes the peel ply is an extremely strong material that you can pull tight over the C/F to give a very even finish. It allows any excess glue to pass through it. The only thing is it gives a matt finish so I didn’t use it on the final layer of C/F I just let it dry on it’s own.

#16 paul11

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Posted 11 October 2009 - 02:42 PM

Now for the mirror cell, for this I laminated 3 layers of Coremat and 4 layers of C/F. I made this up between 2 pieces of 6mm glass.

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#17 paul11

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Posted 11 October 2009 - 02:44 PM

Then I put some weight on it and left it overnight and then made a second one.

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#18 paul11

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Posted 11 October 2009 - 02:47 PM

With a simple jig the band saw cuts perfect circles every time.

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#19 paul11

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Posted 11 October 2009 - 02:50 PM

Here’s a close up of the edge of the disc.

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#20 paul11

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Posted 11 October 2009 - 02:56 PM

Here are the 2 discs, both 10mm thick and top disc on the left has the brass threaded inserts for the adjustment bolts.

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#21 paul11

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Posted 11 October 2009 - 03:01 PM

This is the bottom disc it is matt finish on this side and gloss on the other (outside).

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#22 paul11

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Posted 11 October 2009 - 03:05 PM

1 more

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#23 paul11

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Posted 11 October 2009 - 03:06 PM

with the 9 points and posts

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#24 paul11

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Posted 11 October 2009 - 03:07 PM

with the mirror

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#25 paul11

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Posted 11 October 2009 - 03:08 PM

mirror and outside posts

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