Here are the latest 3D's. This is a beauty and it is cannon proof.

Larry tried machining the pattern
out of particle board at my suggestion but it crumbled. Too bad as it is
readily available everywhere and low cost. Back to the traditional
pattern material of laminated wood. Larry is having some wood
laminated as we speak.

Weight is estimated at 7.5 pounds before any lightening
holes are cut in it with a hole saw. Your option for
inspection or ventilation.

Cost is still airborne. We will have a better handle on cost when
we get some castings.

I'll be using these 3D's in all future layouts and motor
mount designs.
 --
Paul Lamar ...No rotor no motor.

Paul,
I used Craftwood and when it's turned it turns to dust and makes quite a
mess. I turned the convex bowl shape first from a number of layers and then
took a fiberglass mould of that. Then I took another fiberglass mould from
the inside of that mould to form the foundation of the fiberglass pattern. I
used some 5mm thick matting material with glass each side for strength.
The only other thing I had to do was to add the back flange with raised bolt
platforms and anything else raised either externally of internally. This
would include the internal pattern stiffeners and raised areas for bolt
mounting ring and seal mount areas as well as  the external stiffeners and
central locating ring.

I thought Larry might mill the entire finished pattern from a solid block of
something. The 4mm your looking for in the pattern walls won't hold any
strength in Craftwood or particleboard, it may have to be in steel or
aluminium - I can't think of anything else at the moment, perhaps plastic if
it's stiff enough!
George ( down under)

Well there is high density tooling foam but it is expensive.
We are trying to avoid a solid block of aluminum due to the expense.

Paul Lamar ...No rotor no motor.

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