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Concrete filled C-Beam?

Discussion in 'Concepts and Ideas' started by trentaw, Jun 8, 2016.

  1. EvanBruner

    EvanBruner Well-Known
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    I'm wondering if the reaction to the aluminum is normal or if it's due to the anodizing. It would make sense that the hardblok has some kind of etching properties to help with adhesion but it could also be a reaction to the aluminum oxide layer that isn't typical. Aluminum engine blocks aren't anodized as far as I'm aware.
     
  2. Moag

    Moag Veteran
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    Don't really know Evan, I just know there is some kind of reaction going on and by the way I followed your suggestion of trying Moroso Engine Block Filler, not hardblok, so hardblok may be a totally different kettle of fish.

    Here you go @Joe Santarsiero some pics of the process.

    _X8A4095.jpg

    Mixing and pouring. Morose Engine Block Filler.

    _X8A4113.jpg

    Little mud volcano. You could still hear it crackling away after to had solidified.

    _X8A4134.jpg

    Not easy to sand, this was done on a benchtop belt sander (it wasn't happy). So I think I'ill try melting a candle in shallow metal tray to seal the bottom and not totally fill.

    _X8A4136.jpg

    One good solid smack with a ball hammer and a flat punch on a section of railway line on concrete.

    _X8A4138.jpg

    Followed by one solid smack with a small cold chisel.

    _X8A4141.jpg

    Getting there!! From my experience, its hardness is somewhere between marble and concrete.

    _X8A4149.jpg

    Cleaned out. Another mess to clean up.

    _X8A4148.jpg

    What it looks like on the inside after knocking it out..
     
    Joe Santarsiero and Kyo like this.
  3. Rick 2.0

    Rick 2.0 OpenBuilds Team
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    Well isn't that a wee bit corrosive... :eek::eek::eek:
     
  4. Moag

    Moag Veteran
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    Not as bad as it looks Rick, just giving it a bit of a clean with nylon brush and some white vinegar, most of what you see is the grout stuck to the aluminium. Give me a little while to take and process another picture.

    And here's the picture. It has a satiny feel compared to the smoothness on the outside, but certainly messes with the anodising.

    _X8A4150.jpg
     
  5. Phil_Can

    Phil_Can New
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    how did the filler worked out for you? and tips on application? thanks
     
  6. Exodon

    Exodon New
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    Amazing topic...any updates about this technique?
     
  7. Clearly

    Clearly New
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    Sorry to bump an old thread. I'm curious if anyone tried using the block fillers that were mentioned here for this. I have a gallon jug of moroso here and am planning on trying to fill some v slot. My concern is this is obviously an off label use. I'm filling long 2040 v slot towers for a delta printer. There's really not a lot of volume in the middle part I'm going to fill, but they're probably 4 feet long. Any idea of this moroso stuff will cure in one shot at that kind of depth? Or should I do a quarter, wait for it to cure, mix another quarter, wait for that to cure, etc?
     
  8. mikelatnz

    mikelatnz New
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    Polymer concrete is what is used, which is epoxy resign with aggregate.
     
  9. Mmedina

    Mmedina New
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    Interesting. A friend of mine just built a 1500mm x 1500mm c beam CNC. She noticed the torquing the first time she ran 1/8" aluminum. She tried aluminum plates bolted on. She tried filling with cement. But, what finally worked the best was resin epoxy with a steel rod down the center. It also quieted the machine somewhat. So she repeated the process on all axis, and improved her accuracy to .002. Hope this helps!
     
  10. Corey Corbin

    Corey Corbin Well-Known
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    I am curious about this. I have been thinking of the same idea with the steel rods with no epoxy. Is the steel rod free floating inside the alum ext? I was planning on tapping both ends of the steel rod thru gantry upright plates and placing a torque on the nut holding rod pulling the rod tight thru the extrusion like the Tension system pulling the lead screw to eliminate whip. I also have another idea about bolting plates to back of gantry but I was more thinking of 1/8 steel then extra alum plates. Funny then I think all this supporting the alum with steel. Might as well try to build it out of steel. But the rod idea sounds like a viable solution.
     
  11. Mmedina

    Mmedina New
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    Yeah, she used it as a tensioning system. I am getting ready to build a 1500mm x 1500mm and plan to use her idea.
     
  12. gary bergin

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    starting a sphinx type build and need max rigidity contemplating a few of these suggestions does anyone have any tips is the epoxy and sand the best way or the block filler? steel rod or threaded rod thru or nothing tia
     

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