Failing Successfully - FANCY Composite Legs are on the Mold! (4)

We have Fancy Legs and we have NON Fancy Legs. Well today, we're doing once of each!
This is all part of a grand scheme to build our very own solar arch, dinghy davit, hard top, hard dodger, sailing contraptionaire!
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[@Daveincc]

You guys have great risk tolerance ! I know how much those materials cost and how off the cuff you are working. I’d be sick from worrying about things like the vacuum pump quitting at the crucial point or getting through all the molding and finding out I’d completely missed a measurement or angle. Not only are you crushing the execution so far it seems you guys are managing not to take out the stress on each other. I have appreciation and respect of your abilities.

[@gaylacrisler9818]

Unreal! Both of you are incredible workers and you make a great team. I’m just a woman in California who has followed you sailing and now I also love watching you create. Over my head, yes, but very enjoyable for me. 🥰

[@user-wg2hz7iy3v]

You might check with your experts on the vacuum time. In all of my experience with vacuum bagging, I leave the pump on for the full cure time. The vacuum is not sucking the resin out. It is just applying ~14psi of pressure from the atmosphere. The batting is wicking out the excess epoxy. Generally speaking after it is all wetted out, you want to end up with as little epoxy as possible in the final laminate. So bagging is clamping and wicking. I would be concerned if you turned off the vacuum and the seal is not perfect (which is never is), the materials could try to flex back and might open up voids at the edges where the clamping is doing work to hold it all together while it cures. Just thought I would mention it before you make more parts with the vacuum off. While it helps wick out at the start, the main utiliity of the bag is the clamping. Check with you experts, as I am just one non-professional, but thought it might be worth the warning.. Have fun!!

[@jackburns804]

Retired Texan here: You guys are a credit to your generation. Need it , but can’t afford it no problem we’ll just make it and not make it in the US under ideal conditions with the perfect tools. We’ll make it in a foreign country using whatever tools we can scrounge up and do it perfectly. Proud of you. Cannot wait to see the final product. Stay safe you guys.

[@cjshowalter1]

I'm hooked on your adventures, your chemistry, and your mechangineering. But, as an aspiring content creator myself, I admire the exponential gains in the quality of your camera work recently. Bravo!

[@philipwhitmore3276]

You guys are amazing. My suggestion about your vacuum bag is to check with the guy at Duracell project. He’s doing a lot of fiberglass and he’s probably got a good solution for your partial leak.

[@philipblauw4687]

Jade looks like she's going all in on the competitive fencing look. 😆

[@ExpeditionEngineering]

ha! knowing her, she'd probably be expert in no time

[@zacatack8679]

I just finished working on my sailboat (it’s a compac 16) and I didn’t realize how much work it took to do stuff like this, I love it and I’ve been watching your main channel for 1 and a half years and you’re still my fav KZbinr

[@mkllove]

Don't think I've heard you mention an internal structure other than foam coring, but you'll undoubtedly have electrical wiring attached at some point to arch structure... is there a PVC pipe passage or other means of pulling needed cables inside structure ? Adding some pre installed wiring would work, but eventually needs replacement, so I think a passage allowance is more future proof. The electric shears are sharpenable, but you can only do it a few times before tolerances get too loose to shear fibers cleanly... you can take a piece of very fine sandpaper to lightly polish the external or chisel like portion of blades edges. ( usually a 10 degree bevel ) Don't try sharpening the internal faces that rely on close contact, or actual scraping actions against each other to pincer fibers in cutting action... running the sandpaper lengthwise down edge as close to bevel's angle just once or twice will clear some burrs. The blades are really reliant on the scrubbing action on the flattened interior faces to scrub each other and maintain their own edges.

[@mac22011964]

And buy the way, what you are doing is incredible. Been here from the start and cannot believe the “can do” attitude of both of you. Inspirational!

[@user-di9sh3xf4z]

Hi . Couple of tips. Wrap breather around the end of your vacuum hose in the bag to stop the bag sealing off the hose. If you make the vac bag a liitle bigger the first shot and cut the tape from 2 sides you can reuse the bag by retaping those 2 edges and save a bit. you can also reuse all of your breather. Keep it up, I'll be watching.

[@johnhewett2525]

Two tips for you, use a short length of flexible tube/conduit as a stethoscope to find your leaks. Make a small tent over your parts and put the heater inside you will be surprised how much faster your parts will cure.

[@SirCarlosMusicBMI]

I’ve been watching this project from the beginning and I still don’t understand how this process works. Anyways….. I really enjoy watching you two work together. Blessings from Paso Robles, California, Carlos ❤️🙏😀❗️❗️

[@davidflorance7650]

Jade is definitely a keeper, a very capable lady .

[@jonathanmorris8522]

Where are your respirators! Those fumes are bad!!! Love it all though. Thanks for bringing us along. Now set a good example:)

[@rbnhood39]

You two never cease to amaze me. You both jump right into projects that you have never done before and then figure it out and kill it. 🤓

[@Najitaka]

Great progress. Looking forward to seeing it come together. Also, great job on adjusting the music to voice volume level, much better on this video. Thanks.

[@pierremitham2964]

If your mold/form was bigger along all sides by a foot, it would be simpler to vacuum bag. You really want to be vacuum bagging TO something. Usually here you would use a 1 sided bag and sitck it directly to the form (form needs to be waxed) that way the bag forces the curve of the form into the finished part. No need for weights ontop of the bag

[@dustinlaborde4537]

Finding the leaks can be hard at times just make sure you match your beautiful real well that you don't get any little creases and if so, add a little butyl to that area to seal it ... also Put your threw bag valve directly over your part on the breather cloth to get the best overall vacuum, it needs to breathe. Otherwise you're gonna pull plastic into the office and stop it up.

[@joeanco1993]

That's scary, I do understand what your doing!

[@RickFuhrmann]

Again I love watching you both, the love you have for your life, sailing and each other is beyond measure💜💜🙏🏻⚓️🌴

[@terrywells3809]

Here is a trick to get better bag sealing. Instead of butyl tape or in addition to the tape, use acrylic latex caulk.

[@rickynsue]

Boxer app turns your phone into a walkie talkie.

[@ExpeditionEngineering]

Wait really?? Downloading now thank you

[@MadeinSA658]

This new channel is awesome. You guys are rocking it. I can't wait to see the end result. You guys also remind me of my self and my brother 40 years ago, if we couldn't afford to buy it we would make it ourselves. We once made a bubble machine and stripped every small appliance in the house to make it work. We were thrilled once we achieved our mission. Our parents....not so much😂😂😂Thanks for sharing and making entertaining content.

[@jasonargonaut9112]

@12:45 re taking the tape off. You can use either stabilized carbon fiber twill (web lock or glue) or just buy the glue (for example epoxy fixative spray from Sicomin) and spray it yourself on the twill. The glue is compatible with epoxy, invisible in the end product and doesn't affect the final performance, if you didn't apply too much.

[@joshbarnes151]

I truly enjoy watching this channel. That’s all 😁

[@brentwallace67]

I think this channel is starting to find itself - in a good way. Last episode was a bit too close to Expedition Artistry (at least to me), with the slow-mo close ups. But thanks for all the explanation and instruction!

[@grubbypaws3566]

Working hard guys, and it’s coming along. A couple of points make a sub-tent just over your project, this will give you a local heat zone, just like the one you work in only to scale. If you want to use tape try magic tape it uses the same glue as post-its notes, but the best thing it is not porous like masking tape and it doesn’t stick to resin. Something to help with the vacuum is to have a pressure pot and turn it into a larger capacity vacuum chamber, pump-chamber-job, this vacuum for longer with small leaks. ( oh yes you could always get a faster catalyst). Anyway really love the blog can’t wait till next week.👍👍

[@justinecastle-edmonstone9291]

Loving your channels!! Wondered if Pinking sheers would work, these are the zig zag scissors used for materials that fray easily? Was just a thought … you guys are an inspiration… Thankyou for your you tube videos .. 🌻

[@tomatobrush3283]

You guys are nuts building your own carbon fiber solar arch, :D I can't wait to see it on the boat.

[@manuelreygonzalez2716]

One thing about Spain and in Europe in general, you can always find a shop to sharpen your blades. No need to replace, just to sharpen.

[@Axe_North]

Nice odd shirt 😄 ! Love this new channel!

[@joneid1]

U guys work so good together 👌👌😃

[@shluffmuffinsmith7759]

Hey y'all love watching everything from you guys. Is Expedition Engineering going to get it's own Instagram?

[@ExpeditionEngineering]

I just converted mine over recently actually. So yes, hoping to become more active on there as well with the new channel! instagram.com/expedition.engineering/

[@fyrekittah2491]

So excited to see the transformation of Eva!

[@SVSomeday]

Im invested in seeing the final product.

[@colinjacob1702]

Am enjoying this new side of yours, keep up the good work. Sure will be brill when finished.

[@ExpeditionEngineering]

Brill! There's a new abbreviation to add. Thanks 👍

[@Steve-Debs]

P.S. as you’ve probably already started the main top I might be late with a suggestion of a small dip down at the front edge and a small kick up at the back across the width of the entire structure. I’ve seen solid tops on other vessels and they look as though they have just plonked a sheet of whatever on the top to keep the sun off the cockpit. Anyway my 2 bobs worth.

[@obwan7217]

That's a big undertaking.....

[@michaelkearney7923]

Maybe there’s some random stuff around the shop you could borrow that’s better than water to weight down the forms?

[@robm.4512]

👍Sand bags work pretty well.

[@SeizeTomorrowToday]

Another great video all!!

[@pauld9530]

taping the edges if the carbon fibre is a great idea

[@Lmatou77vital]

problème removed masking tape, use de Green one it’s do for peint job and Z for the masking tape, take the green one for cutting paint it is easier to peel off i love follow ont all our sailing treep bye From Québec Can

[@davidperham897]

Hi guys, You’re getting lots of help on the comments! As always Just want to add -- OMG You are doing great & that is a awful lot of work with up & down all day, how are your young bods feeling,knees,back & everything, hurts just to watch BUT You making progress & I look forward to seeing the smile when you get it done Best wishes && all goes well Cdn Dave

[@mac22011964]

Great addition the the growing EE empire. One question, blue water coming over the boat can be extremely heavy, how have you calculated the strength needed?

[@krisk9987]

Very interesting

[@Ucfguy]

I know you and Jade do not post negative things on your pages… which we love! I did wonder however how the generic batteries for the Dewalt devices are holding up? If you like them will you share their link? Debating between two generics or one factory battery.

[@ExpeditionEngineering]

so far they are all working the same, but i can't say I've put them through their paces - hardly pushed them!

[@Ucfguy]

@@ExpeditionEngineering thank you!

[@bigmikes2140]

You should be able to find a heating element like for a small area to put under the layer platform. Should be able to get the temp up

[@julianholland4359]

Well done guys. Presume you will need another former for the other leg as curve goes the other way. Keep going.

[@mikemoran8757]

Hey guys, could you use a light timer to allow your vacuum pump to run while not present? Like when you go on a trip and want house lights to cycle off and on. Love your channel!

[@ExpeditionEngineering]

Clever! Yes we totally could do thag

[@bobbyharrison8223]

This may work better: Don't use masking tape on your carbon fiber...use blue painters tape. If you still want to use masking tape then while removing from the carbon fiber, warm the tape with a hand held hair dryer. The warm tape will release without shredding the carbon fiber.

[@wcgolfpro]

A table would make your life much easier when doing your cutting and manufacturing

[@praeliora]

It may be the glue from the tape that was causing your clippers to clog up, ive had the same issue when cutting leather that I've taped to keep from moving around 🤔

[@vipvetz]

I am not a structural engineer so I was hoping to see how you did your structural analysis. I did not see your engineering analysis for strength loading, both static and dynamic loads. Sea and wind loading forces would come at you 360 degrees spherical. Will the strength of the roof that holds your dinghy with seas crashing into it hold up without breaking?

[@JohanFroloff81]

21:55 you are supposed to divide the epoxy among the two buckets, so it doesn't kick so fast. 😄

[@ExpeditionEngineering]

"supposed to" is pretty subjective. Splitting the pot of good rule of thumb in most situations, it's not needed nor correct in this one

[@JohanFroloff81]

@@ExpeditionEngineering It just looked like you misunderstood the use of the two buckets. If it isn't for splitting the resin in two, then what? Mixing residue?

[@ExpeditionEngineering]

Ah, yeah the idea is to mix in one pot then pour the mixed to a clean pot. That way you don't accidentally apply unmixed resin or hardener to your part. Your idea of splitting the pots is a good idea if you have a short pot life, we have way more time than we need though haha

[@brentclarke1841]

Bravo 👍⛵👍

[@richardnwilson]

Great videos thank you. A thought on speeding up curing. Could you set the curved form on top of sawhorses with the heater underneath after you finish the layup?

[@mikealti]

If starboard side is “fancy leg” I hope the port side will be the “Stanky Leg” 😂👍

[@SRMWorkshop]

We had an electric rotary cloth cutter at work that would breeze through some really thick material without snagging. Who knows if something like that would hold up to the carbon fiber.

[@thomascooley2749]

An inline fan with carbon filter helps keep the fuses down Just make sure its a brushless motor

[@michaellyons6969]

I'm late to the party here but did you consider heated blankets to speed up the cure times?

[@Ww2warbirds]

Can you use a hot knife to cut that with?

[@1971efc]

would a heat sealer not be better for the open ends of the red bags instead of the tape?

[@randompharmacist4850]

Nice to wake up to a new episode!

[@lukecelt9000]

Love both your channels! Question about the fraying carbon fiber when cut - is using a hot knife an option?

[@koosslootweg8500]

Jadetastic!

[@pkane5472]

Wow! Did I learn a lot about carbon fiber forming! Can't wait to see how it gets finished after it's set.... Love it!

[@sailingjano]

Did you tried the blue or green painting tapes. They are less sticky.

[@DanishMule]

did you just time the music and the highfive perfectly? Or did you insert a clap sound and matched it to the music perfectly, witch ever is true I am impressed, well done ;)

[@ExpeditionEngineering]

Appreciate you noticing 😊

[@Steve-Debs]

Bugger, 26 mins came around quickly, but boy ya got a lot done in 26 mins,,, tee hee. Great appropriate music for the time lapse. Gota get you two around to paint the house, probably on take 10 mins looking at the way you work. Ya won’t have to vacuum bag it either, cheers.

[@beemergb]

When laying the carbon or GF up and over bend the sides that makes stronger part , and bonus is of not having the need to cut or sand the sides clean . And please PUT SOME SHOES ON !!

[@donk3094]

Hi Jade and Bret. May I ask when you will again be showing a sailing video? Thank you!!!!!!!!

[@terrayeahright1082]

Love the videos as always however think we might be having flashbacks of Star Wars episode 1 of all the different hair styles. But instead of hair styles how many jade outfits we get. Lol

[@user-lq3ss9xf8c]

Gutsy project, much respect

[@markwng]

Does orange oil mist and composites mix?

[@IU-Uber]

would an electric blanket on low laid on top help keep it warm without heating the whole room? some have a built in 10 hour timers.

[@BrianWetzel]

🤣 Brett... It sure does look like you're milking it😏 Jade 🐝 Bee doing all the work ...... I kid, I kid ..... Nope. Step it up Slacker😂😂😂

[@muskyful]

Great progress! How will these arch legs be anchored to the boat/deck/structure? These legs will produce significant moment loads at point of attachment....so was wondering if there will be a glass/carbon fiber flange foot that is yet to be molded into these legs for a monolithic structure???

[@richardsprow3418]

Good question . This arch has lots of moment forces, from dinghy weight, deck attachments, and side to side sway and no one seems to be engineering that. Seems to be a plan for connected panels not one rigid arch. I worry about structural failure…

[@roberthardy2013]

What about making sandbags instead of water bags ?

[@williamirwin9622]

Ditto to the retired American ✌️❤️🙏

[@SassyPants34]

An idea, sand bags not water bags.

[@sandrareah6764]

Don't you need to put pleets in the tape when your joining the vacum bag up.

[@wadeshore]

I find it amazing that we can’t hear the other noise’s.

[@Roskellan]

AGI - Artificial General Intelligence 🙂

[@garybensel6680]

Can i ask you don't just put the scrap carbon fiber on as second layer to make it stronger?

[@daner.d]

cant you use heat lamps instead of that little heater. with lamps you can direct and distance to get the desired effect your looking for. you could even use a timer so you don't over cook it. stop, I know, genius😁😂

[@user-lg9nq8iy2x]

Just curious, I think I’ve noticed you’ve all been trying to be real quiet when you talk in the shop lately. Seemed like when you all first revealed the space not so much. I assume you all are there mostly in the evenings when others aren’t using the space as much. Are there people sleeping nearby? Then again running power tools would be noisy. Just a silly question about something I think I’m noticing in the videos. Your progress is inspiring, and I look forward to the end results!

[@user-lg9nq8iy2x]

Haha, posted this before finishing the video, seems like there were more people in the space on this video. Totally different vibe.

[@Franko-eg6iu]

Guys please wear mask. Fibers & chemicals in the air. Music got much better Lol 🤠

[@Roskellan]

Be careful sanding carbon fiber or you will damage the weave, plenty of advice on line about that.

[@juanorfi3708]

Comgrats… on… your video. It is.. great that… you… are a… star trek… fan. The… start n’ go…William Shatner… speech style … suits you

[@ExpeditionEngineering]

huh, this feels oddly like a backhanded compliment... on how I talk? lol

[@juanorfi3708]

@@ExpeditionEngineering i do enjoy your videos, but lately it seems you lag on your explanations. Shatner stated that he was instructed to extend his lines hence they were short and lacking context. I wouldn’t like people to think of this. I should have stated this instead. Sorry.

[@ExpeditionEngineering]

Ah, I gotcha. Let me see if I can help the tone of what I think you were intending. "Hey Brett I really enjoy your videos, but I don't fully understand everything that's going on. Would you mind giving a bit more of an explanation for those of us who don't quite follow? Thanks and keep up the great work!"

[@juanorfi3708]

@@ExpeditionEngineering Thanks for your kind words. As I mentioned earlier. Sorry, i really regret being rude. My must sincere apologies.

[@chhindz]

Making carbon fiber for Eva..

[@m.n.a.cruises]

seem there is so much waste though

[@ExpeditionEngineering]

Agreed

[@m.n.a.cruises]

@@ExpeditionEngineering so is it more cost affective than let’s say the “traditional” way? Cas seeing how many extra things you have to buy/use and then just discard makes me think it may not be

[@Franko-eg6iu]

Heads up guys Nuthin personal That up & down noise isn’t music.

[@superformOG]

if it was me I would put a foot through the radio, nothing irks me more then self centered people, probably why i prefer to be out in the middle of an ocean by myself

[@rdwheeldon6840]

Are my ears deceiving me or do you keep saying exhibition engineering? 😂

[@perniciousprogressive8333]

Your continuing ignorance of MSDS & PPEs is making you hard to watch. The harm is cumulative, and it WILL haunt you.