Okay here we go! Actually it went pretty well..... First, the mold:
This step is call "Pre-pregging" where the cloth is soaked with resin by squeegee and roller. Last layers into the mold are the first to get the resin:
Next comes the laying into the mold:
This next step is a cool idea by Mr. Devins(the shop owner). He adds a "bead" of tool putty(a light, fluffy mix used for mold-making) along the corner surface inside the cloth. It serves to solidly form the corner edge of the cloth and also solidly set the honeycomb in place. Nice touch!
Next comes the honeycomb, in this case we used Nomex:
Then comes the inner Kevlar layer. Kevlar has an interesting "damping" effect we are investigating as an alternative to adding a non-structural damping layer over a simple fiberglass inner layer. (Less steps and more stiffness).
Next comes the vacuum bagging for overnight curing with a solid clamping. A layer of very thin "release cloth" is placed over the panels, followed by a layer of fluffy batting for vacuum equalization, then into the bag where it's sealed up and hooked to the vacuum pump.
The whole process should have taken about four hours, start to finish. We spent about six with our "learning curve" included. The panels will come out of the molds tomorrow for trim and "bonding prep" prior to assembly. At that time the various speaker and hardware bolting points will be reinforced against collapse from fastener clamping.
Here's another take on making light panels for less money: Eighth-inch plywood with a honeycomb center! At two ounces per square foot it might be a winner. We're going to do a cabinet this way and see how it sounds. Here's our inch-thick test square:
Here it is next to an inch-thick piece of twenty-ounce per square foot plywood.
Quite a difference! The sound performance remains to be seen. Hopefully both ideas will perform well. Stay tuned!
These next two pix are of a cool guitar body Mr. Devins has been working on. It might Make for an interesting. "bigger" sounding acoustic bass?
This last picture is one of the usual denizens of Mr. Devins' shop: