Loaded Vanguard / Tesseract / Jet Spud: Vacuum Bagging Boards & Enclosures with Carbon

TMI


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@Michaelinvegas TMI, Talk More Intimately? Ok, but this might get weird…:blush:

@whitepony how long would you say it takes you to carbonize a deck? Is it more for aesthetics, or is it more to stiffen the board?

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Lol @Mobutusan … Ur weird

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I think TMI stands for too much information.

Don’t mind @lox897

He’s playing the straight man tonight :stuck_out_tongue_winking_eye:

haha :fearful:

hey man, my tools are few and also not very expensive - its what most people have at my age somewhere in their garage I guess:

  • a spring steel angle tool + 60cm+ ruler - best simple tool I bought for buiding eboards, has helped me soo much with halfway accurate 3D surface measurements

  • a fine pen that will easily draw on wood with a millimeter accuracy

  • vibration sander

  • drill press for halfway accurate holes with drill bits in good condition - my granddad died 4 years ago and thats my heritage :slight_smile:

  • a dremel for all the small stuff and cutting

  • vacuum pump & supplies

so far it has always been for the structural support. when I removed up to 5mm from the tesseract, it became pretty flexy, too flexy for my stiff battery + enclosure concept, so I had to reinforce the board again. same for the topspeed, since I carved deep into the board for the battery pouches.

the vanguard will probably stay without carbon, since I want it flexy and I think the structure isnt majorly affected.

doesnt take too long to do - proper sanding with vibration sander max 1hour, prepartion of vacuum bagging (cutting carbon, breather and bleeder, mixing resin) probably 30min, the laminating process is 30min max, then in the bag and 24hours curing.

after curing the real work begins: cutting out the edges, drilling holes for mounting points and sanding sanding sanding until it looks cool.

so far I have always left the carbon as it is, most people finish it with clear coat. I didnt see the point yet, the raw carbon surface looked pretty great to me so far. :slight_smile:

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What for a beauty she is :kissing_heart:

what cell’s are you using @whitepony

for the small batteries with 40 cells Im using LG HG2, which I think is an unrivaled middleground of current (20A continuous) and capacity (3000mAh). my 10S4P batteries have continuous 80A @ 12Ah, which lasts about 40km!

for my larger projects of 60cells (evolve, trampa), I used Sanyo NCR18650GA, Samsung 35E or LG MJ1 (they are all very similar). they deliver less current (10A continuous), but have a higher capacity of up to 3500mAh.

my latest batteries all have protection cardbord stickers for battery plus-poles and they are reinforced with hot glue (randyc1 was the first who manufactured his battery in that proper fashion!).

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i am just making a small mono drive 6s is best so i can use imax charger. it doesnt have to get me far max 10-12 km but i would welcome and greater distance

i am also open to using old laptop batteries as i have a couple of them laying around

problem with small batteries is: usually your current demands stay the same, lets say 60-80A for starting your board, possibly similar for running high speed, i.e. youll have to use cells that support larger currents per cell, since the load isnt shared by many. the high current chemistries usually have small capacity, so with a small battery you get double punished -> high drain low capacity cells.

on the contrary, if you go big, you get the double benefit: many cells and these cells can afford smaller discharge ratings since so many share the load -> low drain high capacity cells!

i found this video and thought i could do something similar but as a flat pack?can i?

Do you guys think that would work for me?

yea, of course! why wouldnt it?

you said those batteries wont be good

lets keep the thread free of random clutter like recycling laptop batteries - this is about carbon, write me a pm if you want, or open a thread. :wink:

their performance wont be great, theyll drift so you will need a bms, but they are cheap. choices, choices!

This thread just blew my mind! WOW I’m soaking it all in!! Man, this is great stuff!! I read all of this and all of the ES stuff too. I’m hungry for this type of information. @whitepony I’m a fan.

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Could you post a picture of how you laid out your batteries in your banguard build. Im doing a vanguard aswell and am curious how you fit such a large battery so cleanly.

if you want to know more, check the build thread: https://endless-sphere.com/forums/viewtopic.php?f=35&t=80808

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