Strongest resin? Epoxy, or...?

[SgtFang]

I'm getting ready to start on a BIG new prop, but I don't think urethane's going to cut it this time out. The thinnest part of the whole prop needs to be hollow, and about 36" long, but it's also the part with the most stress on it.

I'm still figuring out how it needs to be done, but I'm toying with maybe 1/2" - 3/4" steel pipe for the guts to go in and casting the resin around everything, but then I'll have to worry about resin leaking into the stuff inside and messing the whole thing up.

If I can find something with adequate strength, I'd like to just cast this part in two halves, split down the middle, and have it held together with screws so it could be taken back apart for whatever maintenance it might ever need.

Any thoughts?

-Sarge

 

[exoray]

Fiberglass? or Carbon fiberglass?

 

[SgtFang]

<div class='quotetop'>(exoray @ Aug 25 2006, 08:34 PM) [snapback]1307213[/snapback]</div>

Fiberglass? or Carbon fiberglass?
[/b]

Well, regular fiberglass uses polyester resin that gets more and more brittle with age, but carbon-fiber with maybe epoxy resin would be an intriguing possibility. If at all possible, I'd like to skip the whole laminating process though. ( I hate that part.) Anyone know what kind of resin they make lawn furniture out of?

-Sarge

 

[exoray]

Epoxy or vinyl ester with kevlar or carbon...

I doubt you will find a casting alternative that will offer up the same strength...

 

[Blad]

It may be worth talking to some of the people here who suck.

I mean people who like to use ABS and do vacuum moulding on a regular basis.

Apart from that epoxy and carbon-fibre are the strongest/lightest composites.

 

[SaberFreak]

Durasteel? Interlaced Microfoam Furanium Filaments? Ablative Ceramic Fabric?

If its that big, any chance of making the structure out of metal wireframe and then laying PVC/ABS over it?

Of course kevlar interwoven with carbon fibre is tough and nice, if cost is not a factor...