- March 31st, 2015, 3:33 pm#4830310
Long story short, my Para Goggles are 90 percent done. I was so excited to build them that I didn't even think of documenting the process!!
Nevertheless, here they are:
I used a foam sanding block to smooth out the lightly textured fiberglass frames with great success. I purchased some epoxy to fill in pitting and gaps, mostly around the edges of the frames. Drilling fiberglass was quite the learning experience. I believe I read that you need slow speeds to prevent chipping, but I found out the hard way that the frames tended to chip more the slower the speed. I think the large gaps were the issue mostly.
For the lenses, I opted for a quick solution and cut plastic lenses from an extra CD case I had laying around. The plastic is a tad flimsy, so I think I'll replace them eventually.
I made sure to use light pressure and high speeds with my Dremel and power tools. I sadly had major chipping in areas where I drilled for the various metal snaps, but the Loctite epoxy I use for metal and cement worked beautifully to reconstruct the chipped areas.
The epoxy works like JB Weld, but for me it dries faster and is workable after about an hour.
Attaching the snaps became problematic. I attempted to hammer them in place, but the force needed to fuse the two pieces started chipping the fiberglass. I opted to epoxy them instead. I identified the screws needed for attachment and luckily located a great picture hanging bracket for the top strap connector.
I drew up a quick template for the foam and purchased some gym mat foam. I like it for its sturdiness and because it will repel sweat.
An alright fit.
Here's a rough cut of the Goggles foam. This is the first time I have worked with EVA foam and it's fantastic. It cuts magnificently with an electric coping saw and and be worked with a dremel.
A little heat helped bend the EVA foam to the basic curvature of the frames.
I'm trying to decide on a rubber cement to fix the foam to the goggles, but I'm not sure what type of rubber cement would work well with EVA and fiberglass. If any of you could offer some suggestions, I'd appreciate it.
Nevertheless, here they are:
I used a foam sanding block to smooth out the lightly textured fiberglass frames with great success. I purchased some epoxy to fill in pitting and gaps, mostly around the edges of the frames. Drilling fiberglass was quite the learning experience. I believe I read that you need slow speeds to prevent chipping, but I found out the hard way that the frames tended to chip more the slower the speed. I think the large gaps were the issue mostly.
For the lenses, I opted for a quick solution and cut plastic lenses from an extra CD case I had laying around. The plastic is a tad flimsy, so I think I'll replace them eventually.
I made sure to use light pressure and high speeds with my Dremel and power tools. I sadly had major chipping in areas where I drilled for the various metal snaps, but the Loctite epoxy I use for metal and cement worked beautifully to reconstruct the chipped areas.
The epoxy works like JB Weld, but for me it dries faster and is workable after about an hour.
Attaching the snaps became problematic. I attempted to hammer them in place, but the force needed to fuse the two pieces started chipping the fiberglass. I opted to epoxy them instead. I identified the screws needed for attachment and luckily located a great picture hanging bracket for the top strap connector.
I drew up a quick template for the foam and purchased some gym mat foam. I like it for its sturdiness and because it will repel sweat.
An alright fit.
Here's a rough cut of the Goggles foam. This is the first time I have worked with EVA foam and it's fantastic. It cuts magnificently with an electric coping saw and and be worked with a dremel.
A little heat helped bend the EVA foam to the basic curvature of the frames.
I'm trying to decide on a rubber cement to fix the foam to the goggles, but I'm not sure what type of rubber cement would work well with EVA and fiberglass. If any of you could offer some suggestions, I'd appreciate it.
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"My characters aren't losers. They're rebels. They win by their refusal to play by everyone else's rules." — Harold Ramis