Hi Gang!
Time for an update... What a frustrating weekend! As most of you know we've been having some real issues with the laser cutter. Well... we finally figured out that the software (Lasercut) is the culprit. For those familiar with the "Lasercut" software, Ver 6.0 is the latest. Well, 6.0 is also a BETA version... UGH! And there is a reason it's still a BETA version! The s/w is plagued with so many issues we finally just uninstalled it.
One of the new features to 6.0 is called the "Set Point". This feature allows you to not only see but also change/set the start point where the laser starts to cut your object. It's supposed to look something like this - notice the green circles and the yellow squares
It's not supposed to look like this... I don't even know how many "Set Points" there are in this image!!!!!
The "Set Point" is nothing more that a visual reminder of where the laser cutter will start cutting. It's not a path, layer, mode etch, cut, etc... The S/W is so corrupt that when the file is exported, the s/w is actually referring to these visual reminders as a legitimate path and cuts the line! NOT GOOD!
Insert Face palm here... :facepalm So... We're going to reinstall Ver 5.3, walk through the config file line by line and see if that fixes the issues.
Enough with that! Let's move on to the good stuff! I did make some forward progress. I began by designing a template for a new cover to hide the nose and floor transition to the window. I would like to add some visual interest as well, maybe a vent or screen to allow air flow?
I still have 2 more pieces to design and cut but I like it. Maybe I'll create some custom greeblie boxes similar to the Volvo dash clusters? That would be cool! You guys/gals have any ideas? Let's see some sketches!
I temp added the new "Eye Bolt" greeblies - nice! These are MUCH MORE screen accurate
I then turned my attention to the nose cone panel. In order to apply the skin I need more surface area for the skin to grab so I added these vertical mounting strips. These strips also add depth. This added depth will help in many ways to include meshing the nose to the the front window.
Checking alignment
I then removed it from the platform, flipped it over, found center and started to lay the skin. This was NOT easy
The closer you get to the edge the stiffer and more rigid the skin becomes so more screws were required to keep the skin from popping away from the frame
Because of the vertical strips, this pushed the skin away from the main frame. This resulted in my having to remove almost 3" of material from the underside curve. Another 1/2 - 3/4" and it will be prefect
Still pinching the skin when laid flat.... UGH
I then put it back onto the platform to check the sides for alignment and sanding
So far so good!
I then turned my attention to the two large gaps next to the shelves...
I sketched out the basic shape on a 2x4, took a deep breath and cut this template. But does it fit?
BINGO!
A few minor adjustments and its time for the real thing! Let's do this!
I debated whether to cut the piece below or level with the shelf. It made MORE sense to be level with the shelf. The added surface area gives me a little more room when I begin work on the new Volvo Panels
Note how far the panel is away from the main arch. I'm planning on a metal frame that will mount to the main platform then curve around the main body but not actual mount or add stress to the body panels
I'm going to cut thin strips of the darker material and cover the exposed area to bring the skin level with the shelf
Wasn't able to cover the entire nose... No biggie. The skin will be covered with another layer of 1/8" MDF (or similar) to hide the errors, screws, etc...
Time to cut the other side
PERFECT!
I VERY quickly realized that this was the area I bolted the nose to the frame... UMMM... No access... So, I have to drill 2 holes that will allow me to bolt everything together. But we'll cover those with the removable armor plating. Not sure what those will be made of... we'll burn that bridge when we get to it!
I love that curve! I am a little concerned with the exposed screw heads and how it will affect the second skin layer. Anybody have any ideas?
The laser cutter is now the top priority. We're going back to Lasercut Ver 5.3 to see if that resolves all the issues. Fingers crossed!
A huge thanks to Scott for taking time away from his projects and helping with the nose!
More to Follow!