How to Do Beautiful Enclosures with Custom Fiberglass

There are times when I feel the need to really make a mess. When I think of making messes with a degree of permanency, I think of fiberglass. I also really like the smell, reminds me of a simpler time in 8th grade shop class. But the whole process, including the mess, is worth it for the amazing shapes you can produce for speaker pods and custom enclosures.

Utilizing fiberglass for something like a custom speaker pod for a car is not difficult, but it does tend to be tedious when it comes to the finishing stages. If you have ever done bodywork on a car you know what kind of mess and effort I am talking about. In the video below, I make a simple speaker pod meant for mounting a speaker to the surface of something like a car door.

You can also use a combination of wood and fiberglass to make subwoofer cabinets that are molded to the area around them. You can even replace your entire door panel with a slick custom shaped one with built in speakers  if you’re feeling adventuresome.

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Hackaday Links: July 23, 2017

Hey, you know what’s happening right now? We’re wrapping up the third round of The Hackaday Prize. This challenge, Wheels, Wings, and Walkers, is dedicated to things that move. If it’s a robot, it qualifies, if it’s a plane, it qualifies, if it passes butter, it qualifies. There’s only a short time for you to get your entry in. Do it now. Superliminal advertising.

Speaking of the Hackaday Prize, this project would be a front-runner if only [Peter] would enter it in the competition. It’s one thing to have a cult; I have a cult and a petition to ‘stop’ me.

We were completely unaware of this project, but a few weeks ago, a cubesat was launched from Baikonur. This cubesat contains a gigantic mylar reflector, and once it’s deployed it will be the second brightest object in the night sky after the moon. I don’t know why we haven’t seen this in the press, but if you have any pictures of sightings, drop those in the comments.

In a mere two years, we’ll be looking at the 50th anniversary of the Apollo 11 landing. The mission control center at Johnson Space Center — where these landings were commanded and controlled — is still around, and it’s not in the best shape. There’s a Kickstarter to restore the Apollo Mission Control Center to its former glory. For the consoles, this means restoring them to Apollo 15 operational configuration.

We’ve seen 3D printed remote control airplanes, and at this point, there’s nothing really exceptional about printing a wing. This user on imgur is going a different direction with 3D printed fiberglass molds. Basically, it’s a fuselage for a Mustang that is printed, glued together, with the inside sanded and coated in wax. Two layers (3 oz and 6 oz) fiberglass is laid down with West Systems epoxy. After a few days, the mold is cracked open and a fuselage appears. This looks great, and further refinements of the process can include vapor smoothing of the inside of the mold, a few tabs to make sure the mold halves don’t break when the part is released, and larger parts in general.

The Darknet’s Casefile will take you to the limit of your existing knowledge. Join them, to go on a quest to improve your technical abilities.

This week is Def Con. That means two things. First, we’re on a hardware hunt. If you’ve been dedicating the last few months to #badgelife or other artisanal electronics, we want to hear about it. Second, [Joe Kim] made a graphic of the Tindie dog wearing a Hackaday hoodie and it’s adorable. There are a limited number of stickers of our hacker dog.

Gigabyte launched a single board computer with an Intel Apollo Lake CPU, discrete memory and storage, and a mini PCIe slot. Of course, this is being incorrectly marketed as a ‘Raspberry Pi competitor’, but whatever.

Soluble Molds For Composite Parts

People have been experimenting with 3D printed molds for fiberglass and carbon fiber for a while now, but these molds really aren’t much different from what you could produce with a normal CNC mill. 3D printing opens up a few more options for what you can build including parts that could never be made on any type of mill. The guys at E3D are experimenting with their new dissolvable filament to create incredible parts in carbon fiber.

For the last year, E3D has been playing around with their new soluble filament, Scaffold. This is the water-soluble support material we’ve all been waiting for: just throw it in a bucket of warm water and it disappears. The normal use case for this filament is as a support material, but for these experiments in composites, E3D are just printing whole objects, covering them in carbon fiber prepreg, vacuum bagging them, and allowing them to cure. Once the carbon fiber isn’t floppy and gooey, the support material is dissolved in water, leaving a perfect composite part.

E3D aren’t that experienced with composites, so they handed a bit of filament off to So3D for some additional experimentation. The most impressive part (in the title pic for this post) is a hollow twisted vase object. This would have required a six-part machined mold and would have cost thousands of dollars to fabricate. Additional experiments of embedding ABS parts inside the Scaffold mold were extremely successful.

As you would expect, there are limitations to this process. Since E3D are using a dissolvable mold, this is a one-time deal; you’re not going to be pulling multiple composite parts off a 3D printed mold like you would with a machined mold. Curing the parts in a very hot oven doesn’t work — Scaffold filament starts to sag around 60°C. Using prepreg is recommended over dry fabric and resin, but that seems to be due more to the skill of the person doing the layup rather than an issue with materials.

My DIY BB-8: Problems, Solutions, Lessons Learned

Imagine trying to make a ball-shaped robot that rolls in any direction but with a head that stays on. When I saw the BB-8 droid doing just that in the first Star Wars: The Force Awakens trailer, it was an interesting engineering challenge that I couldn’t resist. All the details for how I made it would fill a book, so here are the highlights: the problems I ran into, how I solved them and what I learned.

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Hackaday Links: August 7, 2016

The Starship Enterprise (no bloody A, B, C, or D) recently got a makeover. It was donated to the Smithsonian, and the workers at the Air and Space Museum took it apart and put it back together. Why? It’s the 50th anniversary of TOS. Hopefully the new show will be using some practical effects.

After years of trying, we’ve finally attained max buzzword. Here’s a pentesting hacker quadcopter drone, “a hacker’s laptop that can fly.” Why would anyone do this? Because, “You need to be close to the wireless signal to be able to read it. [Danger Drone] removes that barrier of physical access.” For just $500, you can do the same thing a coat hanger yagi can do. Amazing.

Q2 reports for 3D printer companies! Lulzbot is going gangbusters yet again. We’re looking at the greatest success of Open Source Hardware here. Stratasys, on the other hand, lost less money in Q2 2016. That’s their good news.

About a year ago, we heard about an LCD that was one inch high and ten inches long. That’s bizarre, but great for rackmount gear. The company behind this weird LCD is updating this weird and wonderful LCD and giving it touchscreen capability.

On this week’s edition of, ‘you’re going to cut your arm off with that thing’, here’s an angle grinder converted into a chainsaw.

A few weeks ago, we posted a link to this video, demonstrating an absurdly clever method for creating a mold for a fiberglass dome. You can just use a pendulum and a pile of dirt. Now, the mold for this fiberglass dome is complete. [J Mantzel] has already pulled 1/8th of his gigantic fiberglass sphere out of his mold, and there are only seven more to go. After that, he’ll find out if these sphere sections actually line up.

UK peeps! Hackaday and Tindie are doing a London Meetup! Details to come, but follow the event page on

I arrived in Vegas a day (or two) early for DEF CON. Instead of contemplating the banality of existence on the strip, I decided on a meetup at the grave of James T. Kirk. The meetup was a huge success. Walking two miles in 115° heat was not a great idea, but I didn’t die.

Pressure-formed Parabolic Mirror from a Mylar Blanket

Parabolic reflectors are pretty handy devices. Whether you’re building a microwave antenna or a long-distance directional microphone, suitable commercial dishes aren’t that hard to come by. But a big, shiny mirror for your solar death-ray needs is another matter, which is where this pressure-formed space blanket mirror might come in handy.

Pressure-forming was a great choice for [NighthawkInLight]’s mirror. We’ve covered pressure-formed plastic domes before, and this process is similar. A sheet of PVC with a recessed air fitting forms the platen. The metallized Mylar space blanket, stretched across a wooden frame to pull out the wrinkles and folds, is applied to a circle of epoxy on the platen. After curing, a few puffs with a bicycle tire pump forms the curve and stretches the film even smoother. [NighthawkInLight]’s first attempt at supporting the film with spray foam insulation was a bust, but the later attempt with fiberglass mesh worked great. A little edge support for the resulting shiny taco shell and the mirror was capable of the required degree of destructive potential.

We doubt this process can be optimized enough to produce astronomy-grade mirrors for visible light, but it still has a lot of potential applications. Maybe a fiberglass radio astronomy dish could be pressure-formed directly with a rig like this?

Fight That Tesla Envy With A Tablet Dash For Your Car

[Aykut Çelik] uses some strong words to describe how he feels about his VW Polo’s current radio set-up. Words like, “useless,” are bandied about. What is a modern man supposed to do with a car that doesn’t have built-in navigation or Bluetooth connectivity with phones? Listen to the radio? There are actual (mostly) self driving cars on the road now. No, [Aykut] moves forward, not backwards.

To fix this horrendous shortcoming in his car’s feature package, he set out to install a tablet in the dash. His blog write-up undersells the amount of work that went into the project, but the video after the break rectifies this misunderstanding. He begins by covering the back of a face-down Samsung tablet with a large sheet of plastic film. Next he lays a sheet of fiberglass over the tablet and paints it with epoxy until it has satisfactorily clung to the back of the casing. Afterwards comes quite a bit of work fitting an off-the-shelf panel display mount to the non-standard hardware. He eventually takes it to a local shop which does the final fitting on the contraption.

The electronics are a hodgepodge of needed parts: An amplifier, to replace the one that was attached to the useless husk of the prior radio set; a CAN shield for an Arduino, so that he could still use the steering wheel buttons; and a Bluetooth shield, so that the Arduino could talk to the tablet. Quite a bit of hacking happened, and the resulting software is on GitHub.

The final assembly went together well. While it’s no Tesla console. It does get over the air updates whenever he feels like writing them. [Aykut] moves forward with the times.

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