Making of the SNX Hull

That or someone has pulled some major thread hijacking ;)

I'll have a thread in new product release and for sale sections once I get a few more things straightened out and molds finished for an adjustable reduction nozzle, coupler cover, and low profile OEM style air intake. In the meantime, I'll still be posting pics of the new molds and prototype parts and hopefully one day actual ride report for the hull.


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Plan for today was to infuse the first of the test poles, but I ran out of MTI hose and flow media.

Test poles are going to be a few ounces heavier due to the aluminum plate and extra carbon. I was going to remove some of the layers in the body of the pole, but without being able to test it myself (next pole is going straight to a tester), I would rather be a few ounces too heavy than a few too light. Probably added about a pound and a half to two pounds in total. Really not all that much.

Same layup for the top half of the pole as last time (75oz, 19.7 twill/15.6 triax/20 uni/19.7 twill).

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Bottom of the pole received additional reinforcements in the tongue area.

19.7 twill, 15.6 triax, 20 uni, 3mm soric core

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Added two layers of 20oz unidirectional carbon at ~45* to the left and right of center. Then 8oz glass tape to isolate the aluminum plate from the carbon. Cut and bent a 4" x 11" 3/16th 6061 plate.

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Another layer of glass tape for isolation.

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15.6oz triax over the tongue area. 20 uni next.

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Triax

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19.7 twill

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Total layup in the body is 110.6oz @ a .248 thickness. Layup in the tongue is 166.2 @ .50 thickness. Fiber orientation was a big focus on the pole. Fibers were aligned at 0*, 45*, 90*, 120*, 240* and 315*.

Body
0* = 59.7oz
90* = 30.1oz
120* = 10.4oz
240* = 10.4oz

Tongue
0* = 59.7oz
90* = 35.3oz
120* = 15.6oz
240* = 15.6oz
45* = 20oz
315* = 20oz

Should have my consumables in by Friday and hopefully this pole finished by next Monday.

Also in the works...

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Whats up with this adjustable reduction nozzle?

It's in the conceptual design phase (ie my head and a little in solidworks). I will probably start putting some serious work into it after these poles go out and I mold the air intakes.


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Very cool!

Quick question, why does the aluminum have to be isolated from the carbon with fiberglass?

In the galvanic series, carbon has a higher nobility than aluminum. So in the presence of an electrolyte, it will cause galvanic corrosion to the aluminum (less noble metal). You will see this around aluminum inserts in direct contact with carbon, or stainless steel, while exposed to salt water. Since the plate in the pole would probably never have an electrolyte present around it, I doubt this would ever be an issue. Still, I would rather take the extra step to isolate the plate from the carbon.

The motor mount inserts are both anodized and isolated for this reason. The thick aluminum oxide layer insulates the base aluminum and makes the surface non-conductive, helping to halt galvanic corrosion. Glass is again overkill, but worth the extra step.


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Coupler cover & 3/4" ply
6b2fda2258bc9eacc96c4d25fbbb278d.jpg


Body filler. Ready for high build primer
32eef15d4da971085d8f6c64d0cbcc39.jpg


Poly high build
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Duratec+high gloss. 320/600/1k/2k/3k/m105/205
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Sealer/semi perm, gelcoat, and 3 layers of surfacing veil & 2 mat tomorrow. Going to infuse the rest of the reinforcements on Friday. Last mold I infused came out perfect, but didn't have a thick enough skin coat and ended up with ever so slight print through from the infused roving/mat combo. Goal going forward is for all molds to have a production quality gelcoat finish with zero void reinforcements.

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Coupler cover & 3/4" ply
6b2fda2258bc9eacc96c4d25fbbb278d.jpg


Body filler. Ready for high build primer
32eef15d4da971085d8f6c64d0cbcc39.jpg


Poly high build
be74ddfa19a3ddd863c36ec766b05b22.jpg


Duratec+high gloss. 320/600/1k/2k/3k/m105/205
a438831215cba42acf54ae56d94dfd4f.jpg

0f87080b2c881d87651f92ab562a920e.jpg


Sealer/semi perm, gelcoat, and 3 layers of surfacing veil & 2 mat tomorrow. Going to infuse the rest of the reinforcements on Friday. Last mold I infused came out perfect, but didn't have a thick enough skin coat and ended up with ever so slight print through from the infused roving/mat combo. Goal going forward is for all molds to have a production quality gelcoat finish with zero void reinforcements.

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That's so sweet, I need to make a trip down there so you can teach me how do this stuff, so dam clean looking
 
Thanks Brandon!

Sure. You're welcome to come down anytime. There is always sanding to do around here.


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