Fuzzy homemade micarta

D

DirtyBrad

Joined
Dec 20, 2006
Messages
79
I followed the blue jean instructions on British Blades, but used West System 105 resin with the 206 hardener.

First batch was 16 layers of denim. About a one foot by two inch piece clamped between oak boards with 3" c-clamps. When I cut a cross-section of that the next day, it seemed extremely fuzzy, so I figured I didn't get enough penetration with the epoxy.

The next day I did about 45 layers of t-shirt fabric. I was careful to use plenty of the epoxy. With each layer, I patted it down well and thoroughly wetted out the material. I also crept the clamps up until they were cranked on as hard as I could get them.

The cross section cut the next day felt way smoother, but when I test-filed a corner at about 45 degrees, it also seemed really fuzzy. I tried sanding, but it still felt to me like the raw fabric.

So, seems like the resin's not getting in there enough. Not too surprising with the denim and just using c-clamps. But, like I said, I thought I'd completely wet out the t-shirt material when building up the stack, so I was surprised. I'm also wondering if the epoxy is maybe not thin enough.

Anyway, I'd be happy to hear any thoughts or suggestions for better results on the next batch.
 
I would have to say either try a different epoxy or add a little more hardener.
It sounds more like the epoxy is not setting up properly or is not mixed well enough. I have had problems like this with fiberglass before.
 
and dont clamp it up too tight.i think i squeezed all the resin out of a couple of blocks before.
 
caseynz said:
and dont clamp it up too tight.i think i squeezed all the resin out of a couple of blocks before.
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The more epoxy you leave in the better the finish. Will be a heavier but polish better. As long as it it a solid piece give it a coat of superglue or epoxy then finish it. Edited to add that denim takes a lot of epoxy to really wet out all the way. How much did you use and how big was the piece roughly?
 
Both pieces were about 12" x 2". The denim was 16 layers, the t-shirt was about 45 layers.

I figured the denim needed either more epoxy or more pressure to get in since it's fairly dense. When I did the t-shirt, I tried to really soak it. Like I said, I was sure each piece was completely wetted out before laying the next one down.

Do you mean there will always be some fuzz after shaping that will require another layer of epoxy to cover before final polishing?
 
There will almost always be some fuzz when you first sand it. What grit did you finish to? Most of the time once it is finished to 220 grit or so it is almost gone. Hit it with a buffer and it will be fine. Most of the time I tell people that use my stuff to take it to 400-600 grit then buff for a shiny finish or take it to 220 then coat with epoxy then refinish it at 220 for a bit more grip. Edited again lol. It is possible to make stuff with no fuzz, but it takes a lot of epoxy and little pressure. You have to use a vacuum to remove any air bubbles. Makes it not as dense if that makes sense and leaves a lot of epoxy in the cloth. I do not think it is worth doing it this way since in the end with a little more finish work you get a better piece doing roughly the way you first described. Everyone is a little different of course.
 
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Oh, that's promising. Maybe I'm just over reacting. I sawed off one end, then hit the top corner with a file. I gave it a quick hit with whatever was on the bench. I can't remember if it was 100 or 200.
 
I have made lots of it,using a lot different materials.I have only used fiberglass resin,and clamp it between 2 boards using C-clamps and I clamp it as tight as I can and have always had good luck.

God bless,Keith
 
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