Board:
The board is from 30kg/m3 XPS with Airex75kg/m2 Top and bottom (flat part). It is shorter than the first one, length is 133x55x13.5cm.
The main compartment was cut with hotwire (nichrome 0.5mm)
same for the “connector” compartment
The slots for square cfk bars and the connection to the main compartment were made with an over router.
Connector plate
Square CFK tubes
connecting piece of 5mm cfk to spread load to the board and to the top
Vacuum bagged the connector box, 2 layers of cfk 200g.
connector plate with inserts was laminated into place to be flush with the main compartment,
Stainless steel inseerts to hold the mast
5mm full carbon board to fix the mast (is a bit overkill an heavy but strong)
Sandwich from 5mm CFK board an 5mm and Airex75kg/m2. Inside 1 layer of glass 280g/m3, outside 200g/m3 CFK. 3d Printed caps to cover and hold mast nut inserts in place
Glued in bottom plate and laminated the edge of the inside
Laminated front compartment for receiver and GPS. The hatch is connected through a 16mm electrical tube to the main compartment.
12mm Airex board glued on top. The4 cutouts on the side are for handle inserts.
3d printed hadle inserts, covered with 3mm CFK Board. 4mm Stainless rod to hold a Velcro loop covered with neoprene
Magnet cap with magnets to find the insert after laminating
Made a screw router addon for the Dremel flex wire extension
Routed slots for printes inserts with nuts to fix stuff later. Nuts were filled with play doh like sealing called “Coltogum”
Flatened the walls with filler.
Frame with M5 square nuts to screw the lid
Consists of 2 parts, frame an screw cover
Routed holes for the frame with a template and Dremel
Glued it in
Laminated the inside of the compartment with 2x 280g glass. Reason for glass is transparency to find the inserts!
Cut the outline with hot wire
Shaped the rails (cut and sanded)
I did not like the shape of the back, the round corners of the template were a mistake
I had to change it! glued some pieces with 1k foam
better