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> Carbon Fibre/kevlar Zaurus Body, Feeler for interest
post Mar 25 2006, 07:57 PM
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Joined: 15-March 06
Member No.: 9,366

Greetings. I am new to the forum with the purchase of my new SL-C1k from Conics. I am trying to gauge interest in customized composite body replacements for the clamshell design. Since I own a 1k and the body style is common amongst 1k-3200, I have decided to do only this model as a pilot. I will be investigating into either a full kevlar/CF and epoxy resin replacement body to fit your Z, hand molded from my own.

I also have a connection for vinyl auto graphics who has agreed to provide customized logos at a very fair price (<$5 per iteration). This means that your choice of graphics at approximately $5 per color will be laser cut and placed directly on the composite body before it is coated in a gloss epoxy resin. This will give a very clean and professional look to your Zaurus, and is far, far more durable than the plastic outer casing. You will also experience a degree of weight savings over the plastic/metalic bodies.

At this time I am modeling only the top screen portion and the bottom cover of the case, to include the battery cover. The inner case (keyboard surround) is outside my ability to produce to a high degree of accuracy, but can be done on a custom basis for a larger amount of cash if you're composite obsessed wink.gif

Carbon fiber is available in a number of colors, but I will be using the standard carbon pattern that you see on performance cars, etc. The kevlar is standard tan/creme color, and looks quite industrial. Kevlar will be cheaper as it is easier to work with, and less material expense.

I'm shooting to keep the cost under $100 for the complete carbon body set, or kevlar. This is of little or no profit to me, but gives me some nice experience in working with the materials. Please let me know if this sort of arrangement would be of interest to you. Also in the works may be a molded, exact form fitting case for the clamshell 1000 and beyond series. Again, at a cost of less than $100 if possible, including a custom graphic. The case material is strong enough to withstand being thrown at a brick wall by a pro baseball player and will be padded to withstand the most clumsy zaurus user. Oh, and waterproof, and floating. And with less bulk and weight than a leather case (which is only about $25 less than my target price for real carbon fiber!) biggrin.gif

Keep in mind though, carbon fiber is in a general shortage right now due to Airbus, Boeing, and the US's lust for carbon fighter aircraft >.>
So, these prices are totally tentative.

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post Jul 10 2006, 08:59 AM
Post #2

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From: Bath, UK
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Dont suppose you have a link to a DIY carbon fiber tutorial, im intrugied if it is as easy as you say

Take a look at something like this:


You need a vacuum pump and an oven. Other than that, it can be quite simple (prepreg) or quite complex (determining resin/filler percentages), though for this application, the absolute strength of the material is not that important so the filler/resin calculations and uniformity are not too troublesome (from what I remember of my University placement manufacturing composites).

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Posts in this topic
maytagman   Carbon Fibre/kevlar Zaurus Body   Mar 25 2006, 07:57 PM
BarryW   I think if you do build one and show the quality, ...   Mar 25 2006, 08:12 PM
Cresho   QUOTE(BarryW @ Mar 25 2006, 08:12 PM)I think ...   Mar 25 2006, 09:40 PM
BarryW   QUOTE(Cresho @ Mar 25 2006, 08:40 PM)QUOTE(Ba...   Mar 25 2006, 11:54 PM
maytagman   Well buying a sample amount of material is very ex...   Mar 25 2006, 08:19 PM
Srono   Interesting. but i would like to see the real one ...   Mar 26 2006, 12:01 AM
Da_Blitz   If the pics are good i would buy one What i am lo...   Mar 26 2006, 02:31 AM
pepilo   I'am also interested.   Mar 26 2006, 07:51 AM
maytagman   The problem with the keyboard surround is that it ...   Mar 26 2006, 09:25 AM
rrnwexec   I am interested too. Even better if it is "mo...   Mar 26 2006, 10:44 AM
cycle_55   sign me up. I'd take two depending on the cost...   Mar 26 2006, 11:19 AM
zeigerpuppy   interested, especially if it allows access to the ...   Mar 26 2006, 01:22 PM
bam   same here, a little extra space, just enough to sl...   Mar 26 2006, 02:56 PM
Da_Blitz   I always have liked how people are so paranoid abo...   Mar 26 2006, 03:42 PM
alban42   I am VERY interested I have a Z3200 on Order ... P...   Mar 27 2006, 12:41 AM
ztep   I'm also interested in buying one of these.   Mar 27 2006, 03:23 AM
Fushnchupsh   Yeah, I'd totally be interested! Keep us ...   Mar 27 2006, 11:33 AM
InSearchOf   Yea... keep us posted... if they are reasonably pr...   Mar 27 2006, 11:42 AM
maytagman   Okay, I have a mold struck on my C1000 and I'v...   Mar 27 2006, 03:33 PM
Da_Blitz   cool might shoot you off some diagarams soon, luki...   Mar 28 2006, 03:38 AM
kahm   I'd have to put my vote in for an exact replic...   Mar 31 2006, 09:05 AM
jerrybme   Great idea! I'm interested too; at minimum...   Mar 31 2006, 12:08 PM
BarryW   Some pics of the build process would be pretty coo...   Mar 31 2006, 05:12 PM
adf   QUOTE(BarryW @ Apr 1 2006, 01:12 AM)Some pics...   Mar 31 2006, 06:38 PM
BarryW   QUOTE(adf @ Mar 31 2006, 05:38 PM)QUOTE(Barry...   Mar 31 2006, 07:28 PM
Cresho   QUOTE(BarryW @ Mar 31 2006, 07:28 PM)QUOTE(ad...   Mar 31 2006, 08:16 PM
BarryW   Well I got it!! Now I'm trying to con...   Apr 1 2006, 12:09 AM
Da_Blitz   https://www.oesf.org/forums/index.php?showtopic=18...   Apr 1 2006, 01:32 AM
BarryW   QUOTE(Da_Blitz @ Apr 1 2006, 12:32 AM)https:/...   Apr 1 2006, 02:40 AM
BarryW   Who Hoo!! Got OpenZ to boot! Missed ...   Apr 1 2006, 11:30 AM
Da_Blitz   Just make sure there is no CF or SD card in the sl...   Apr 2 2006, 02:33 AM
maytagman   Still waiting on kevlar to get here Was cheap, so ...   Apr 6 2006, 10:30 AM
Da_Blitz   cant wait, thanks for the update   Apr 7 2006, 12:14 AM
komoman   Any pics yet? Just won an auction for a 3100. No...   Apr 11 2006, 01:49 PM
raduga   a few possible bodies: (and lots of questions...   Apr 11 2006, 03:17 PM
maytagman   lol, people have some big ambitions. I'll answ...   Apr 13 2006, 12:43 PM
raduga   Thank you, maytagman, for a clear and succinct res...   Apr 13 2006, 08:26 PM
Antikx   My *dream list* would be a bit of a larger case th...   Apr 13 2006, 01:32 PM
InSearchOf   Sorry Maytagman for hijacking you thread... but An...   Apr 13 2006, 03:29 PM
Antikx   QUOTE(InSearchOf @ Apr 13 2006, 05:29 PM)Sorr...   Apr 13 2006, 09:11 PM
Da_Blitz   Dont suppose you have a link to a DIY carbon fiber...   Apr 13 2006, 05:56 PM
scottielittle   i'm interested in the case as well. I don...   Apr 16 2006, 11:14 PM
BarryW   Hey, did you get the stuff you need yet?? What do...   Apr 21 2006, 09:38 AM
InSearchOf   QUOTEHey, did you get the stuff you need yet?? Wha...   Apr 29 2006, 05:01 AM
BarryW   Anybody heard from this guy? He glue himself to h...   Jul 10 2006, 08:07 AM
Ferret-Simpson   In a reference to this and the PPZ (PocketPenguinZ...   Jul 10 2006, 08:22 AM
lardman   QUOTEDont suppose you have a link to a DIY carbon ...   Jul 10 2006, 08:59 AM

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