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The John Lee Top Mold
Photo by David Johnson
created 11/7/2002
submitted 11/11/2002 12:22:32 PM
This photo shows the completed top mold of Yale's 2003 ASC entry, The John Lee. The mold was made by spraying chopper glass on top of a foam plug. The members in the picture are washing the PVA (a release agent used in the mold making) out of the mold to prepare it for layup. The mold is supported by a metal frame in order to provide support for the weak chopper glass mold. Metal was used rather than wood to allow for high temperature cures.

Team Lux Top Mold.JPG | 2272 x 1704 | image/pjpeg | djohnson
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Detail View of The John Lee Foam Stack
Photo by
David Johnson
created 7/12/2002
submitted 11/15/2002 07:37:36 PM
This photo shows the foam stack for the top plug of The John Lee inside its crate shortly before shipping out for machining. The photo clearly shows the disadvantage of using epoxy for gluing foam blocks together. The low viscosity epoxy ran out from between the blocks and coated portions of the next layer of the foam stack. Ultimately this caused no problems in machining, but it wasted glue.
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