Week of March 8-14 2004 This week on Cal SMV-- Part I: The Top On Saturday, we sanded, sanded, and then sanded again the female top mold (see picture below). After taking the trouble spots in the back and the right wheel well down to 600, we, after a few hours of sanding, rinsing and sanding, we had her at 1500 all the way around. There were still divots in the back which were mended with gel coat… and that will now need to be sanded… Part II: The Bottom Also on Saturday, after completing the waxing system we attached the flange to the male mold (using the same three score screws as last time) and filled in the cracks around the bottom with clay… until we ran out of clay and started using the wax from the waxing system (see pictures below). Gelcoat was then applied, thus commencing with the creation of the bottom female mold (see pictures below). Part III: The Engine On Tuesday, attempt number one was made in inserting the sleeve into the engine case. Galling (deep gouges and grooves) occurred on the surfaces of the sleeve and cylinder when we tried inserting the sleeve. The sleeve got hung up because of this; however we didn't realize what was happening and continued to exert pressure to force the sleeve in. The pressure became to great for the case to withstand, causing it to fail. A new sleeve has been created and a second attempt is planned for next week. Wet sanding the female Attaching the flange to the bottom male The bottom, complete with flange and plenty of clay (the blue stuff around the bottom) Mike spraying gelcoat The bottom post spraying gelcoat Sexy, very sexy The engine before attempting to insert the sleeve The engine and the hydraulic press Scott McCormick (from the engine lab in Hesse) inserting the sleeve after cooling and coating in Locktite Using hydraulic press to insert the sleeve The sleeve post inserting (you can see the galling) The engine after the inserting (you can see the crack) Previous | Features | Next Contact Cal SMV © 2004 - Berkeley, CA Contact Webmaster