LightSward
Flashlight Enthusiast
The 36 inch Gorilla is freed from the molding process. Here are some photos of the removal and initial prep work. The outside of the Gorilla reflector is not very pretty, I know what I will do on future reflectors to have a much nicer edge and reduced weight. I went over kill to prevent reflector 'wobble'. The gorilla reflector weighs about 20 pounds plus or minus. I'll get a final weight next few days.
Mold is removed from the 36 inch Gorilla
I removed the mold using destructive method. The use of hand rubbed candle wax and beeswax made all the difference in the easy removal of the mold. Once I settle on a good design, I will use a single concrete mold for production.
The top of the mold seen in early photo
Here you can see the top of the mold, that is visible in previous photo.
The 36 inch Gorilla is ready for edge shaping
Here the Gorilla is ready for edge trimming, sanding and wax cleaning. The reflector surface came out smooth, the outside of the reflector shell is rough and lumpy...a result of some 'strengthening' experiments I tried. I want to keep the reflector rigid and not 'wobble', but lower weight to easily handle reflector.
Fiberglass shell is translucent prior to coatings
This has been a great learning experience.
Finished spot filling, ready for sanding and final surface prep
With all the reflector side spot filling complete, the reflector is left to "cure" overnight before final inspection and sanding
Checking smoothness of the Reflector surface to be...outside is left somewhat rough. My next reflector will be much prettier!
The Gorilla reflector surface came off the mold quite smooth. I washed the wax off and the whole reflector with soap and water. After, I started spot filling small voids left during the glassing.
A side view
Here the reflector is rotated on a Lazy Suzie for spot filling and inspection.
I will finish the basic set up tomorrow and place a 100 watt HID bulb in with spherical reflector for the back light.
:thumbsup::thumbsup::thumbsup::thumbsup::thumbsup::thumbsup:
Mold is removed from the 36 inch Gorilla
I removed the mold using destructive method. The use of hand rubbed candle wax and beeswax made all the difference in the easy removal of the mold. Once I settle on a good design, I will use a single concrete mold for production.
The top of the mold seen in early photo
Here you can see the top of the mold, that is visible in previous photo.
The 36 inch Gorilla is ready for edge shaping
Here the Gorilla is ready for edge trimming, sanding and wax cleaning. The reflector surface came out smooth, the outside of the reflector shell is rough and lumpy...a result of some 'strengthening' experiments I tried. I want to keep the reflector rigid and not 'wobble', but lower weight to easily handle reflector.
Fiberglass shell is translucent prior to coatings
This has been a great learning experience.
Finished spot filling, ready for sanding and final surface prep
With all the reflector side spot filling complete, the reflector is left to "cure" overnight before final inspection and sanding
Checking smoothness of the Reflector surface to be...outside is left somewhat rough. My next reflector will be much prettier!
The Gorilla reflector surface came off the mold quite smooth. I washed the wax off and the whole reflector with soap and water. After, I started spot filling small voids left during the glassing.
A side view
Here the reflector is rotated on a Lazy Suzie for spot filling and inspection.
I will finish the basic set up tomorrow and place a 100 watt HID bulb in with spherical reflector for the back light.
:thumbsup::thumbsup::thumbsup::thumbsup::thumbsup::thumbsup:
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