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Carbon fiber panel

 
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geoff Combs



Joined: 04 Jan 2008
Posts: 10

PostPosted: Tue Mar 03, 2009 9:32 pm    Post subject: Carbon fiber panel Reply with quote

Here are some pictures of my carbon fiber panel and lower centerconsole. All parts weigh 2lbs. These will be available very soon if anyone is
interested. See more pictures at the link below

http://albums.phanfare.com/isolated/L5LenCCI/7068012/3161550

Geoff


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PostPosted: Tue Mar 03, 2009 11:09 pm    Post subject: Carbon fiber panel Reply with quote

Geoff,
Sometimes it sucks to be an early adopter. You miss so many
"goodies" that come along. Clearly the design & execution are more than
just a goodie. Really superior work. I notice the rendering is
significantly different that the finished product in that the radio
stack is shifted right. Good call for side by side glass is ideal (for
me). The only downside is no throttle quadrant in this configuration.
Are you going to offer that as an option?
I see you installed AA's OH console. How about trying your hand
at one of those too? There are so many things not... ideal about that
unit.

Well done!
Robin
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PostPosted: Tue Mar 03, 2009 11:14 pm    Post subject: Carbon fiber panel Reply with quote

Geoff,
I watched the video of the CNC and block of aluminum. Is solid
metal required to form CF parts. Can carbon come off a wood form.

Robin


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tomhanaway



Joined: 12 Aug 2006
Posts: 111
Location: Murphy, NC

PostPosted: Wed Mar 04, 2009 2:58 am    Post subject: Re: Carbon fiber panel Reply with quote

Geoff,
Gorgeous work. How tall is the panel directly in front of the pilot
or copilot. I'm working on my panel right now and could easily make the switch.
My layout is two AFS Advanced 4500's directly in front of pilot so this layout makes sense.
My biggest concern is whether the Infinity grips will still fit
(I'm assuming some cutback of stick).

Also, when do you anticipate available?
Availability through you or a vendor?

Thanks,
Tom H.


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msausen



Joined: 25 Oct 2007
Posts: 559
Location: Appleton, WI USA

PostPosted: Wed Mar 04, 2009 5:20 am    Post subject: Carbon fiber panel Reply with quote

Bigger question, how much $$$.

Michael

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PostPosted: Wed Mar 04, 2009 6:34 am    Post subject: Carbon fiber panel Reply with quote

Geoff C

Nice work and a lot of it. Question C Where did you get that compact pnuematic panel saw that I saw in one of the first few photos? I have been looking for one of those for a while.
Thanks C
JOhn G. 409 Do Not Archive

[quote] Subject: Carbon fiber panel
From: g.combs58(at)yahoo.com
Date: Tue C 3 Mar 2009 21:32:48 -0800
To: rv10-list(at)matronics.com

[quote][b]


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PostPosted: Wed Mar 04, 2009 6:34 am    Post subject: Carbon fiber panel Reply with quote

Geoff:

Wow. I wish I had my own backyard CNC and a block of aluminum the
size of the panel. Significant cost for the first one. I bet you will
be able to recoup your investment. Looks great.
Fred.


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partner14



Joined: 12 Jan 2008
Posts: 540
Location: Granbury Texas

PostPosted: Wed Mar 04, 2009 8:13 am    Post subject: Carbon fiber panel Reply with quote

I saw your email last night.... and agree with Robin.... it seems no matter what we put together, there's always going to be some smart ass that puts us all to shame. All I managed to do last night was forward your email to my brother, his shop foreman, and the guy in his shop who handles all the Solid Works projects. They used Solid Works to design my panel including splitting it into 3 pieces and designing bracketry to support all the avionics. I can't wait to hear back from the shop. Hopefully they won't want me to tear out the panel and start over!
GREAT job Geoff.
Don McDonald

--- On Tue, 3/3/09, geoff Combs <g.combs58(at)yahoo.com> wrote:

Quote:

From: geoff Combs <g.combs58(at)yahoo.com>
Subject: Carbon fiber panel
To: rv10-list(at)matronics.com
Date: Tuesday, March 3, 2009, 9:32 PM

--> RV10-List message posted by: "geoff Combs" <g.combs58(at)yahoo.com (g.combs58(at)yahoo.com)>

Here are some pictures of my carbon fiber panel and lower centerconsole. All parts weigh 2lbs. These will be available very soon if anyone is
interested. See more pictures at the link below

http://albums.phanfare.com/isolated/L5LenCCI/7068012/3161550

Geoff

--------
Build QB RV-10 N829GW


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=233076#233076


Attachments:

http://forums.matronics.com//files/img_1558_137.jpg
http://forums.matronics.com//files/img_1552_172.jpg
http://www.matronics.com/contri================



[quote][b]


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Don A. McDonald
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AV8ORJWC



Joined: 13 Jul 2006
Posts: 1149
Location: Aurora, Oregon "Home of VANS"

PostPosted: Wed Mar 04, 2009 9:11 am    Post subject: Carbon fiber panel Reply with quote

I loved the website, the photo slide dissolves and the process video. I was blown away at the thought of the cost to most of us builders to make the mold out of aluminum. Wow, as I watched the coolant and shards hit the camera lens. I forgot for a moment that I was not there - Live. Then I scratched my head and wondered why with the most beautiful panel ever developed you would resort to using stock rudder pedals and a ill fitting fiberglass overhead plenum. If you decide to cast an aluminum mold to retro the canopy, let me know, I will prepurchase one to help with that ingot cost. By the way, though one NACA might work, there are lots of times where two are more comfortable for both the fuel tunnel cooling and the passengers under the glass "south of the Mason-Dixon".

It made for a wonderful evening and a lot of dreaming on several fronts. Composites Unlimited told me that knowledge and skill of Solidworks 3D could have a major impact on the quality of fabricated pieces. You have driven that point home with a Grand Slam. I am not sure they will abandon their mold technology for aluminum ingots though. They tend to assign their 5 axis router to build up foam substrate instead. I would wager that CJ is looking for another cool piece of machinery to play with.

The ability to do quadrant installations as well as vernier cables would open a much wider arena for sales. If your lower console can adapt for a VP200 display, then I am sold! Both Rob Hickman and Stein are probably redirecting their customers to your site as we read this.

Congrats Geoff (and belated happy 50th)

John - watching in awe as that bar moves UP so rapidly.

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Don McDonald
Sent: Wednesday, March 04, 2009 8:12 AM
To: rv10-list(at)matronics.com
Subject: Re: Carbon fiber panel


I saw your email last night.... and agree with Robin.... it seems no matter what we put together, there's always going to be some smart ass that puts us all to shame. All I managed to do last night was forward your email to my brother, his shop foreman, and the guy in his shop who handles all the Solid Works projects. They used Solid Works to design my panel including splitting it into 3 pieces and designing bracketry to support all the avionics. I can't wait to hear back from the shop. Hopefully they won't want me to tear out the panel and start over!

GREAT job Geoff.

Don McDonald

--- On Tue, 3/3/09, geoff Combs <g.combs58(at)yahoo.com> wrote:
Quote:


From: geoff Combs <g.combs58(at)yahoo.com>
Subject: Carbon fiber panel
To: rv10-list(at)matronics.com
Date: Tuesday, March 3, 2009, 9:32 PM
--> RV10-List message posted by: "geoff Combs" <g.combs58(at)yahoo.com>

Here are some pictures of my carbon fiber panel and lower centerconsole. All parts weigh 2lbs. These will be available very soon if anyone is
interested. See more pictures at the link below

http://albums.phanfare.com/isolated/L5LenCCI/7068012/3161550

Geoff

--------
Build QB RV-10 N829GW




Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=233076#233076




Attachments:

http://forums.matronics.com//files/img_1558_137.jpg
http://forums.matronics.com//files/img_1552_172.jpg


<Bsp;--> http://www.matronics.com/contri================







[quote] [/b][/b][/b][/b][b]http://www.matronics.com/Navigator?RV10-List[b][/b][b]http://forums.matronics.com[b][/b]http://www.matronics.com/contribution [b]


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PostPosted: Wed Mar 04, 2009 10:17 am    Post subject: Carbon fiber panel Reply with quote

Fred,
The idea of a garage/hangar/backyard CNC is no longer
unthinkable. I own 5 CNC's now with my first one (Used HAAS VF-5)
costing about the same price as a nice flying RV-10 and my last of the
same model running less than $60K in better condition than the first
unit. I have also picked up a cherry VF-1 for $11,000. Crazy great
value. Unfortunately these are very though times for manufacturing and
many places are being forced to liquidate with few to no US buyers.
Expensive equipment significantly underutilized.
Now the chunks of metal are not going down in price, that is why
I asked about milling wood to use as the mold. We regularly mill blocks
of aluminum or steel that size but we have to make two of each (male &
female) with a lot more considerations for end product wall thickness,
mold heating & cooling, mechanical part ejection...
I recall Chris (perfectly good plane) on the list purchased a
mini "bedroom" CNC for small projects. I think he said the software
learning curve what the greatest challenge.

Robin
Do Not Archive

--


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PostPosted: Wed Mar 04, 2009 11:03 am    Post subject: Carbon fiber panel Reply with quote

John,

I have a full size drawing up on my wall of Geoff’s panel, so that I can play with equipment placement. I’ve haven’t checked depth yet, but it does appear that the VP-200 display shouldn’t be an issue for the lower console.

I’m still debating on whether or not if I want to go with a quadrant or not. That’s what both my son and I are familiar with, but I think with Geoff’s panel, I’m considering going the traditional route. If I hadn’t been laid off this past month, I would have probably purchased a quadrant and given it to Geoff for prototyping.

Having the opportunity to see Geoff’s work in person, I can verify that he does great work. His aluminum center console is a work of art too.

bob

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of John Cox
Sent: Wednesday, March 04, 2009 12:10 PM
To: rv10-list(at)matronics.com
Subject: RE: Carbon fiber panel



I loved the website, the photo slide dissolves and the process video. I was blown away at the thought of the cost to most of us builders to make the mold out of aluminum. Wow, as I watched the coolant and shards hit the camera lens. I forgot for a moment that I was not there - Live. Then I scratched my head and wondered why with the most beautiful panel ever developed you would resort to using stock rudder pedals and a ill fitting fiberglass overhead plenum. If you decide to cast an aluminum mold to retro the canopy, let me know, I will prepurchase one to help with that ingot cost. By the way, though one NACA might work, there are lots of times where two are more comfortable for both the fuel tunnel cooling and the passengers under the glass "south of the Mason-Dixon".

It made for a wonderful evening and a lot of dreaming on several fronts. Composites Unlimited told me that knowledge and skill of Solidworks 3D could have a major impact on the quality of fabricated pieces. You have driven that point home with a Grand Slam. I am not sure they will abandon their mold technology for aluminum ingots though. They tend to assign their 5 axis router to build up foam substrate instead. I would wager that CJ is looking for another cool piece of machinery to play with.

The ability to do quadrant installations as well as vernier cables would open a much wider arena for sales. If your lower console can adapt for a VP200 display, then I am sold! Both Rob Hickman and Stein are probably redirecting their customers to your site as we read this.

Congrats Geoff (and belated happy 50th)

John - watching in awe as that bar moves UP so rapidly.

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Don McDonald
Sent: Wednesday, March 04, 2009 8:12 AM
To: rv10-list(at)matronics.com
Subject: Re: Carbon fiber panel


I saw your email last night.... and agree with Robin.... it seems no matter what we put together, there's always going to be some smart ass that puts us all to shame. All I managed to do last night was forward your email to my brother, his shop foreman, and the guy in his shop who handles all the Solid Works projects. They used Solid Works to design my panel including splitting it into 3 pieces and designing bracketry to support all the avionics. I can't wait to hear back from the shop. Hopefully they won't want me to tear out the panel and start over!

GREAT job Geoff.

Don McDonald

--- On Tue, 3/3/09, geoff Combs <g.combs58(at)yahoo.com> wrote:
Quote:


From: geoff Combs <g.combs58(at)yahoo.com>
Subject: Carbon fiber panel
To: rv10-list(at)matronics.com
Date: Tuesday, March 3, 2009, 9:32 PM
--> RV10-List message posted by: "geoff Combs" <g.combs58(at)yahoo.com>

Here are some pictures of my carbon fiber panel and lower centerconsole. All parts weigh 2lbs. These will be available very soon if anyone is
interested. See more pictures at the link below

http://albums.phanfare.com/isolated/L5LenCCI/7068012/3161550

Geoff

--------
Build QB RV-10 N829GW




Read this topic online here:

http://forums.matronics.com/viewtopic.php?p=233076#233076




Attachments:

http://forums.matronics.com//files/img_1558_137.jpg
http://forums.matronics.com//files/img_1552_172.jpg


<Bsp;--> http://www.matronics.com/contri================







Quote:
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geoff Combs



Joined: 04 Jan 2008
Posts: 10

PostPosted: Wed Mar 04, 2009 11:05 am    Post subject: Re: Carbon fiber panel Reply with quote

I will try and answer most of the questions. Yes we will have a configuration for the throttle quadrants. This was already in the works.
We used a aluminum mold because it was cheaper than making a master
part and then making a carbon fiber mold. These parts are all Carbon fiber prepreg layups. Sometimes when carbon fiber or fiberglass molds are made there are voids that are not visible on the surface. When go and layup in these molds and vacuum bag and autoclave the parts it
opens these voids up and the parts have flaws as well as the molds break down much quicker. As for wood molds they do work OK but do not last like aluminum. As for the overhead console that everyone seems to be all fired up about. I chose to do what I did because it was very close to what I wanted. Yes it had some fit issues but it was OK. It was not AA overhead. It was much cheaper than making one for myself. It was not my perfect solution but it was 85% what I wanted. As for the little die grinder it is for the tool & die industry. Turns about 30,000 I think cuts thru
aluminum and fiberglass like butter.
Also if you use a throttle quadrant instead on the push pull you can just put a plate over that area and cut out the 3 locations. You could then put switches on the plate. Also if you do not want the center console or side panels we have a cap the fits over the bottom middle area that finishes off the panel real nice. As for cost somewhere between $0.00 and $1,200.00


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PostPosted: Wed Mar 04, 2009 11:06 am    Post subject: Carbon fiber panel Reply with quote

Robin and gang;

Like everybody else who has posted a reply, I was just blown away seeing
someone "doing it right" I made my carbon fiber panel by overlaying the
accuracy avionics fiberglass one. I had to learn some vaccum bagging
techniques to apply it the best I could.

I saw an interesting segment on "How it's made" on the discovery channel
last night that showed how a complex auto part was made. The part that
is not in the books is how they use the layers and then actually draw
the epoxy resin into the mold/layers of carbon fiber. I never thought
of that.

I saw a pic of Geoff's panel on Vansairforce the other day. I have
been drooling since.

Oh well, mine will still have that "retro look" Smile.

Dr Fred.

Robin Marks wrote:
[quote]

Fred,
The idea of a garage/hangar/backyard CNC is no longer
unthinkable. I own 5 CNC's now with my first one (Used HAAS VF-5)
costing about the same price as a nice flying RV-10 and my last of the
same model running less than $60K in better condition than the first
unit. I have also picked up a cherry VF-1 for $11,000. Crazy great
value. Unfortunately these are very though times for manufacturing and
many places are being forced to liquidate with few to no US buyers.
Expensive equipment significantly underutilized.
Now the chunks of metal are not going down in price, that is why
I asked about milling wood to use as the mold. We regularly mill blocks
of aluminum or steel that size but we have to make two of each (male &
female) with a lot more considerations for end product wall thickness,
mold heating & cooling, mechanical part ejection...
I recall Chris (perfectly good plane) on the list purchased a
mini "bedroom" CNC for small projects. I think he said the software
learning curve what the greatest challenge.

Robin
Do Not Archive

--


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jim(at)CombsFive.Com
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PostPosted: Wed Mar 04, 2009 11:11 am    Post subject: Carbon fiber panel Reply with quote

here is also a FREE CNC package that runs on a PC and is used for hobbyists as well as big companies. Go check out EMC2. It comes fully bundled with Ubuntu.Jim C--> RV10-List message posted by: "Robin Marks" <robin1(at)mrmoisture.com>Fred, The idea of a garage/hangar/backyard CNC is no longerunthinkable. I own 5 CNC's now with my first one (Used HAAS VF-5)costing about the same price as a nice flying RV-10 and my last of thesame model running less than $60K in better condition than the firstunit. I have also picked up a cherry VF-1 for $11,000. Crazy greatvalue. Unfortunately these are very though times for manufacturing andmany places are being forced to liquidate with few to no US buyers.Expensive equipment significantly underutilized. Now the chunks of metal are not going down in price, that is whyI asked about milling wood to use as the mold. We regularly mill blocksof aluminum or steel that size but we have to make two of each (male &female) with a lot more considerations for end product wall thickness,mold heating & cooling, mechanical part ejection... I recall Chris (perfectly good plane) on the list purchased amini "bedroom" CNC for small projects. I think he said the softwarelearning curve what the greatest challenge.RobinDo Not Archive--

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PostPosted: Wed Mar 04, 2009 11:25 am    Post subject: Carbon fiber panel Reply with quote

put me on the list for the $0.00 one. (haha)
Your work truly is amazing and inspiring.
Pascal
--------------------------------------------------
From: "geoff Combs" <g.combs58(at)yahoo.com>
Sent: Wednesday, March 04, 2009 11:05 AM
To: <rv10-list(at)matronics.com>
Subject: Re: Carbon fiber panel

Quote:


I will try and answer most of the questions. Yes we will have a
configuration for the throttle quadrants. This was already in the works.
We used a aluminum mold because it was cheaper than making a master
part and then making a carbon fiber mold. These parts are all Carbon fiber
prepreg layups. Sometimes when carbon fiber or fiberglass molds are made
there are voids that are not visible on the surface. When go and layup in
these molds and vacuum bag and autoclave the parts it
opens these voids up and the parts have flaws as well as the molds break
down much quicker. As for wood molds they do work OK but do not last like
aluminum. As for the overhead console that everyone seems to be all fired
up about. I chose to do what I did because it was very close to what I
wanted. Yes it had some fit issues but it was OK. It was not AA overhead.
It was much cheaper than making one for myself. It was not my perfect
solution but it was 85% what I wanted. As for the little die grinder it is
for the tool & die industry. Turns about 30,000 I think cuts thru
aluminum and fiberglass like butter.
Also if you use a throttle quadrant instead on the push pull you can just
put a plate over that area and cut out the 3 locations. You could then put
switches on the plate. Also if you do not want the center console or side
panels we have a cap the fits over the bottom middle area that finishes
off the panel real nice. As for cost somewhere between $0.00 and $1,200.00

--------
Build QB RV-10 N829GW


Read this topic online here:

http://forums.matronics.com/viewtopic.php?p 33191#233191





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AV8ORJWC



Joined: 13 Jul 2006
Posts: 1149
Location: Aurora, Oregon "Home of VANS"

PostPosted: Wed Mar 04, 2009 12:47 pm    Post subject: Carbon fiber panel Reply with quote

Geoff - you are an inspiration.

The median price of $900.00 looks right ON... Not too Cold, Not too Hot.
Ready with a security deposit$$. You are one of the first to acknowledge
the poor mold voids that have lead to such Vans part manufacturing QC
issues and the dozens of hours of redux. With the aluminum female mold
you could run refrigerant veins to slow the layup time and speed the
ramp up time on the autoclave heat up. The process is still pure
Starwars.

The pencil die grinder is often sold for around a $100 from A/S or Tool
Yard, but Harbor Freight has them at times for $9.99 on special. They
either work or don't. Three years of heavy use and I have given two as
gifts to friends. Another buddy burned up my Dremel using electricity
for extended periods. Uses Home Depot 0.125" shaft Dremel products from
buffing wheels, cutoff, sanding or die grinding inserts. Is great for
punching quick holes through composite for nutplate attachments or
shaping an edge.

John N49CX

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PostPosted: Wed Mar 04, 2009 1:33 pm    Post subject: Carbon fiber panel Reply with quote

I have a hardcopy of the panel. He was kind enough to give me a printed copy to drool over as I plan my panel the last time I was at his shop. I have it up on a wall outside my office in the basement. I keep re-arranging the stack every couple of weeks. I figure I’ll have it perfect by the time I have to actually install it.

I like Paul’s pedal’s too. Now if we can just get everyone to order a set, so Paul can mass produce them and get the price down!

The nice thing about being unemployed at the moment is that my fuselage kit arrived the week before and I have plenty of time on my hands. Banging rivets is a great way to relief the stress and pains of the old job.

It is definitely that time of year in which the OSH countdown clock begins. I may be camping in a tent this year, but I’ll be there.

Bob

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From: John Cox [mailto:johnwcox(at)pacificnw.com]
Sent: Wednesday, March 04, 2009 4:11 PM
To: rv(at)thelefflers.com
Subject: FW: Carbon fiber panel





From: John Cox
Sent: Wednesday, March 04, 2009 1:08 PM
To: 'rvmail(at)thelefflers.com'
Subject: RE: Carbon fiber panel



I would love to find out the format of your full size drawing or if Geoff is making it available. I have a 3D Full size buildup using Foamcore of mine with Twin G900s or twin AFS4500. It has the King Air style eyebrow row with backup Steam Gauges, Autopilot and Caution/Warning lights. The switch row is at the bottom, deletions and modification of the kneecap line compensates for Infinity Grips. I wanted a VP200 with a totally different overhead console including their Engine Start buttons and map lights with eyeball ducts. The upper panel is canted 70 degrees, the switches and VP are at 60 degrees for improved ergonomics.

I will absolutely go with the Throttle Quad.

I was hit with Workman's Comp (five months in 2008) then a "sue us for your back pay cause we don't think you can't prove it happened at the airline". My attorney is confident of a settlement. Death of both Parents and of course the 401k conversion to the 200.5K that Deems and I talk offline about. I meant to get out before the election and will for the rest of my life remember why (but did not) in 2008. Wishing you the best at a solid future income stream. Oregon has gone from 5.9 to 10.2 unemployment and I am forecasting 12 to 15% before the dust settles. My real estate is being pressed down 40% to align with what used to be stocks. My bonds are another story. At 60, I am rethinking everything but stopping RV-10 production. I have secured the name RV10.PRO and will go Build Assist to play with Jesse as soon as the FAA reapproves his ops and Two Weeks to Taxi.

Geoff has me dreaming of being 50 again.

I picked up a virgin Lancair IVP "Dolly Parton" cowl and am reverse lofting it for my Carbon Fibre "Pamela Sue" for the RV10. It is conceptual to allow twin turbo or angle valve Lycoming placement onto the stock mounting bracket. Will require composite prop ONLY. It has the Sbach snarl nostrils and buxomly firm exhaust curves just like its namesake. It just does not yet have the penciled eyebrows. I tried for a subtle plug of Paul Grimstad's pedals this morning. Deems will be the first one flying them. He is getting the Medical review this AM.

Looking forward to seeing you at OSH '09.

John

From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of Bob Leffler
Sent: Wednesday, March 04, 2009 11:02 AM
To: rv10-list(at)matronics.com
Subject: RE: Carbon fiber panel



John,

I have a full size drawing up on my wall of Geoff’s panel, so that I can play with equipment placement. I’ve haven’t checked depth yet, but it does appear that the VP-200 display shouldn’t be an issue for the lower console.

I’m still debating on whether or not if I want to go with a quadrant or not. That’s what both my son and I are familiar with, but I think with Geoff’s panel, I’m considering going the traditional route. If I hadn’t been laid off this past month, I would have probably purchased a quadrant and given it to Geoff for prototyping.

Having the opportunity to see Geoff’s work in person, I can verify that he does great work. His aluminum center console is a work of art too.

bob
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