Clean the TGP rod but DO NOT SCRATCH the rod. If we damage the rod, it will be difficult or impossible to slide off the completed shafts.
Mount the rod between centers on the lathe. Just loose enough that it turns freely. Cover the bed and surrounding area with several thicknesses of newspaper.
CHECK TO BE SURE THE LATHE IS NOT PLUGGED IN! We will turn the rod by hand. You will need masking tape, a clean brush, and the roll of stretch wrap.
You need to cover the TGP rod with waxed paper. This acts as the mold release.
The waxed paper needs to be 5 feet long.
Rip the waxed paper down it's length. Approximately half the roll width.
Cut one end of the paper approximately at a 45 degree angle.
You will need two strips of 4oz glass cloth. BE VERY NEAT, CAUTIOUS AND CAREFUL HANDLING ROLLS OF CLOTH.
Cut two strips using the straight edge.
You will also need two strips of 2.3 oz. glass cloth.
Carefully re-roll all glass cloth.
Cut carefully without snagging glass threads.
When you have cut the two pieces of 4oz and the two pieces of 2.3oz, roll them up to keep them clean and make them easier to handle.
Trim off any stray threads.
Return all tools, re-roll all cloth and clean off cutting station.
You will need the spool of glass roving.
You will also need the spool of carbon fiber roving.
Begin by taping the end of the waxed paper to the mandrel.
Turn the mandrel by hand as you tightly wrap the waxed paper.
Keep the paper at an angle to the mandrel such that approximately half of the strip overlaps the paper already on the mandrel. This is like 1/2 lap rolled roofing.
When you get to the end of the mandrel, cut off excess approximately at a 45 degree angle.
Tightly tape the end of the waxed paper.
Make sure the paper is smooth and tight on the mandrel. All masking tape will be applied on the ends of the mandrel. There is approximately 3 inches at each end of the mandrel where all tape can be applied and no resin should be applied. Keep these ends dry and tight.
Apply a layer of stretch wrap. Cover the entire mandrel as well as the live centers on the lathe.
Keep the stretch wrap fairly tight and apply at an angle so that you overlap each layer.
At the end of the mandrel, cover the tape end and the lathe center.
Smooth down the stretch wrap.
Prepare all four pieces of cloth. You will use them in the following order: 2.3oz, 4oz, 4oz, 2.3oz.
The first strip of 2.3oz cloth is applied DRY to the stretch wrap. Like the waxed paper, cut the end at an angle.
You will fasten this dry cloth to the mandrel with masking tape.
Make sure the cloth is fastened tightly to the mandrel with the tape. Wrap at an angle and keep the cloth smooth and tight as you wrap.
Keep all wrinkles to a minimum! Overlap 1/2 of the cloth as you wrap.
As with the waxed paper, when you get to the end, cut off excess cloth.
Use masking tape to fasten the end of the cloth.
The last 2 inches of the mandrel is where all the strips will be fastened. Wrap some tape tightly in this area to be sure that this first layer of glass does not shift or slip under future layers.
The end should be as smooth and tight as possible.