Island Mode - A New Grip (The Trigger Guard)
I've been stuck on an island in the Philippines for the longest time and lately I have begun thinking about taking this gun out for a spin. But I also wanted to do a bit of work on it. Specifically I wanted to do a better grip. Back when I "built" this gun, the plan was always to make a grip out of my special mix of chopped carbon fiber and micro balloons like the one I did for my Pathos:
But I only had time to do a Polymorph grip so that's what's been on the gun until now:
The carbon and micro balloon mix is super light and pretty easy to shape, but I don't have any of my composites stuff with me here but a friend of mine had a small set of epoxy resin with a bit left over and I figured there would just be enough to make the new grip if I mix it with saw dust. It will be more ghetto, or rather
island work than normally but that's fine with me.
But I also wanted to raise the handle as much as possible this time.
First step was to remove the old Polymorp grip which was easy. Just dunk the whole handle in hot water for a few mins and then pull it off:
You might notice that this Poly grip is actually a bit higher than the one in the first pic - once I had a bit of time on my Indo trip that the gun was made for, I took a Dremel to it and got rid of as much of the black plastic above the middle finger as I dared at the time. Well, time has made me braver since then so now, I wanted to take off material all the way up the underside of the trigger:
As you can see, I have chopped off the original trigger guard. Before this, I had actually tried to heat, bend it and epoxy it in place in its new location but I couldn't get a good hold with the glue and finally the whole thing snapped cuz I was too impatient when I heated it. So, now I had to make a new trigger guard. Also, the reason the build-up of epoxy + saw dust in the pics above is fairly large is because I cut quite a lot off material off in that area when I wanted to bend the original guard.
Luckily, my friend with the left over epoxy also had some carbon fiber. It was bought for a failed attempt to repair some cracked fins but they had bought UD fiber which is not my favorite, but beggars can't be choosers and as I said, this is an "island build" so having any CF is lucky in the first place
To make a "plug", I used some very cheap epoxy putty from the local fishing supply store (they use this to glue their local banca outrigger boats together so you can get it everywhere and it's like USD 2 for 500g or so):
And then, importantly, I fixed the handle to a chair with packing tape - the fixation, not the chair nor tape is the important part;-):
(Might be hard to see, but the plug is covered in clear packing tape for an easier release of the CF)
Whenever I can, I like to wet up the CF on a film or piece of glass before placing it on the part:
(To the left you can see that I did place UD in both directions)
After each strip (13 in all) was wetted out and placed on the handle, I used electricians tape for compaction. This is where having the handle firmly fixed in place paid off as it made it a whole lot easier to get proper - and even - pressure on the tape as it was pulled down on each side:
Pro Tip;-)
Do NOT wrap the tape
around the part like you would wrap bicycle handlebars or a tennis racket - there's a huge risk of the laminate shifting to one side without you noticing. Instead, cut loads of strips of tape long enough to wrap around the part and latch onto itself. This way, you can keep even pressure side to side on the laminate so it will stay put and also, since this type of tape really only sticks well to itself it's important that the are strips long enough for the tape to "reach itself". Also, wipe the handle down with acetone after the layup and even a few times while you do the taping as the tape really doesn't work if just a bit of resin gets on it.
(Full disclosure; the reason I am adamant about doing it this way is that this is actually the second trigger guard I made... When I did the first one, I wrapped the tape continuously around the handle and the CF shifted under the tape and while the guard came out almost alright, it was a whole lot thinner on one side).
But basically, just keep putting strips of tape on the part:
When done, the gimp can sleep...;-):
In order to not have to do much sawing or sanding it's a good idea to cut the excess laminate off while the resin is "green" (not so hard enough that you can't cut it with a knife but not so soft that the CF will move around, either):
Here it is after having fully cured, a bit of sanding and after I knocked off the plug again:
I had to cut a slot for the trigger to be mounted through as the guard will be epoxied in place (the original also has such a slot):
(I later went to my friend's freedive shop to drill out the ends of the slot but for some reason I don't have any pics of the guard mounted before I started working on the grip).
I have to say that the CF guard came out better than I thought - after I learned the taping trick of only using strips and not doing one continuous wrap - and I am quite surprised with how good compaction I got on the laminate just by using tape. No visible voids at all and the part is very, very stiff.