DIY composite handle materials

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Paliden

Joined
Mar 26, 2006
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I am trying to get some advice on making my own composite handle materials. i have tried a couple diffrent sealants/adheasives but havent found the magic material. have thought about trying some of the stabilization solutions but am unsure of their adheasion properties. Any advice would be appreaciated. thanks
 
A little more info on what you are using for the "composite" would help.
Also, what have you used that failed?
Stacy
 
i am useing duck cloth for the bulk material. i have had some sucess useing polyester resin but it sets up to fast and it doesent seem to penetrate the threads as well as i would like .
 
Thanks.

There are two considerations when making home brew composites. First, it won't be like Micarta. Second, it will require using materials and procedures that are not specifically designed to go together.

With that caveat, you will need a laminate that will be able to absorb the resin, and a resin that will be able to penetrate the laminate. The cotton duck cloth you are using should be washed well to remove the sizing from it.It will need to be fully dried,too. This will allow the resin to penetrate better. Then you need the thinnest resin you can get. Several of the West System, or System Three resins will do this. You want a water clear resin ,too. The drying speed can be tailored by the catalyst used, the temperature, and the size and shape of the mixing pot. Some study on resins and how they catalyze will help you with understanding how that works.
Contact the tech department at the resin supplier and talk or email them what you are doing and the requirements.
That info should be something like:

Laminating 1" to 1.5" thickness of canvas cloth layers.
Resin pot life required is 1-3 hours ( or more)
Cure time 24-72 hours.
Working temperature 60-80F
Usu of final laminate - Knife Handles

I know you will hear all sorts of ways to slow the cure rate down, but the best and proper way is to use the right resin and catalyst mix. Thinning with acetone, using a different quantity of catalyst, etc. will result in less than satisfactory results ( unless you are satisfied with poor results).

You will need to make a press capable of clamping the material under a good bit of pressure. A small hydraulic jack and an "H" frame will work well. You will want to soak the cloth in the resin to allow the resin to absorb into the fibers. A pot life of 3-4 hours will be a great asset here, as it will allow better penetration. If you can rig up a pressure/vacuum pot from a paint pot and put the container of cloth/resin in it the vac/pressure cycle will really make the absorption complete. After a 15 minute vac/pressure treatment, laminate the cloth and apply a ton or more of pressure. Remember, one ton PSI pressure applied to a 6"X2" block is only 166 PSI. Let it remain clamped for 72 hours at least, and then allow to cure for a week before doing anything with it.

Stacy
 
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Just to set the record straight, Micarta is a phenolic resin impregnated product. You can not make Micarta or anything like it. You can make polyester or epoxy impregnated laminates, which will work like Micarta, but will be softer and gummier. Polishing the home made stuff is a bit of a trick in many cases. The true epoxy resins make the best stuff, but are more expensive than polyester resin.
Stacy
 
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