Carbon Fibre/kevlar Zaurus Body, Feeler for interest Options

[maytagman]

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

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!)

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.

Opinions?

[lardman]

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:

http://www.netcomposites.com/education.asp

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).


Si