Can't believe I had never posted this on the DB.... Sorry Foxfish:friday
I put this thread together for a Hawaii forum where there isn't a whole lot of action in the gun building department. So since I had already done the work I figure Ill post it here as well... Keep in mind this thread is for a board where there is not a lot of gun building experience. I know there are tons of guys with lots of experience here and many with more than myself so take it for what its worth...Hope you enjoy.
As some of you may know I have been building guns quite consistantly for the past 2 years or so. I dont claim to be an expert by any means but I do enjoy the process and my guns seem to be making a few guys very happy so its been something that has brought me a lot of joy lately.
Anyway, I have learned a lot of valuable information by reading other peoples build processes here and on other forums, and I appreciate the time others have taken to inform the rest of the dive community. I have recently been given the challenge of building a hybrid by a friend and current dive partner. This is my first hybrid so what better way to teach others than by posting all the mistakes I'm going to make :lol:
I hope that this process will do one of two things, either dissuade people from trying to build their own gun after they realize how much work really goes into a custom gun and buy one from me or the many other custom builders out there :mrgreen: .... or inspire someone to build their own, help them realize that mistakes are going to happen regardless of how much experience you have and how we fix or utilize those mistakes is what really defines us as woodworkers.
I dont plan on giving all my secrets away but will gladly walk through some basic steps that I hope will help people on their own projects. I have aquired many tools over time that helps these builds move a lot quicker but keep in mind that minimal tools are needed to build a gun. One could get away with a Table saw (preferably 10" or bigger) a router and router table (a table is easy to make if you dont have one), a drill press, and chisels. Take my experience for what its worth, feel free to criticize but be sure that all criticism is constructive for the sake of others.
I will try to keep up with this as much as I can, I am not a very organized person but will do my best, enjoy!
pecs:
60" carbon fiber hybrid with Paduak stock and Aimrite Venom barrel
Partially enclosed composite track
Daryl Wong 3 hole muzzle
Neptonics "reef" trigger mech
Neptonics SS handle frame and remote trigger
60" threaded shaft with slip tip (type has not been decided yet)
First step of the build was deciding on the materials to use. Cost was a factor and since this is my first hybrid my part of the build is pro-bono so to speak... that is unless Xterminator strikes it big in Vegas this week 8)
That being said we chose paduak as the material for the stock. I think I payed around $6-9 a board foot for a nice piece of quarter sawn paduak compared to $28 a board foot for teak. This wood is a dense hardwood with a very rich rose color.
Dont be discouraged by the dark brown color you will find when you look at the wood on the rack. Without a UV inhibitor this wood will darken to a bland brownish purple very quickly but a quick sanding will bring out the original color. Many gun builders, including Phil Herranan, prefer padauk to many other woods due to its rich color, workability, and density. Riffe even started making guns out of Padauk as of recent.
Another reason for our choice was the color will go very nicely with the red kevlar wrap that the Aimrite barrel has.
the next step in this process was laminating the stock (this process is almost exactly what I do for my all wood stocks). Due to the material I had available (4quarter sawn) I was forced to laminate the short stock for this gun. For a stock this short (30" or so) you could get away with a solid piece but good luck finding one big enough. In order to utilize the most out of this wood I chose to use 6 laminates to achieve a thickness of 2.125" wide and 2" tall. After jointing an edge I cut the 6" wide material into 2" strips. I then split them in half on the table saw into 3/8 wide strips.
Notice the grain in the picture below. It is very important to reverse the grain patern with each laminate otherwise laminating is completely usless. This insures that all the natural forces within the wood grain work against each other and cancel each other out rather than with each other and bending or warping the stock.
before gluing I sand the laminates in a cross hatch pattern with 60grit sand paper. This ensures a mechanical bond with the epoxy between laminates. Running wood through a surfacer will often leave a very smooth surface which can lead to disaster when laminating. I then wipe each laminate off with acetone. The effects of this is debatable. I believe it clears each surface of oils, natural resins and dust which might interfere with the bonding process. Others believe that, additionally, the acetone which soaks into the wood grain, will also draw the epoxy deeper into the pours but with the evaporation rate of acetone I think its minimal.
The last step in this process is epoxy and clamping. I use Fiberglass Hawaii's 2 part epoxy which is compatible with West Systems products. Due to the deep voids in this grain I have added microfibers to the mix to insure the epoxy fills all these voids before curing. I use a disposable brush and coat each side of the laminate thoroughly with epoxy. When clamping it is important to clamp to a straight surface and use as many clamps (preferably the same type) with even pressure throughout. It is also important to not over tighten the clamps. You want to tighten until you see the epoxy being squeezed out of the joint, too much will starve the joint of epoxy and weaken it.
Once the stock has been clamped it is important to leave it in the clamps for 24 hours or more. You want to ensure the epoxy has fully cured before continuing with the build. With my all wood stocks I will take them out of the clamps and often let them hang for up to a month. this insures that any additional movement can be fixed before the track is cut and the gun is shaped. If you cut the track too soon and the gun bows on you often times you are SOL so take your time.
Since this is such a short piece and there are so many laminates curing should not be an issue. I will leave it in the clamps for a while and probably start the next step by the end of the week.
I put this thread together for a Hawaii forum where there isn't a whole lot of action in the gun building department. So since I had already done the work I figure Ill post it here as well... Keep in mind this thread is for a board where there is not a lot of gun building experience. I know there are tons of guys with lots of experience here and many with more than myself so take it for what its worth...Hope you enjoy.
As some of you may know I have been building guns quite consistantly for the past 2 years or so. I dont claim to be an expert by any means but I do enjoy the process and my guns seem to be making a few guys very happy so its been something that has brought me a lot of joy lately.
Anyway, I have learned a lot of valuable information by reading other peoples build processes here and on other forums, and I appreciate the time others have taken to inform the rest of the dive community. I have recently been given the challenge of building a hybrid by a friend and current dive partner. This is my first hybrid so what better way to teach others than by posting all the mistakes I'm going to make :lol:
I hope that this process will do one of two things, either dissuade people from trying to build their own gun after they realize how much work really goes into a custom gun and buy one from me or the many other custom builders out there :mrgreen: .... or inspire someone to build their own, help them realize that mistakes are going to happen regardless of how much experience you have and how we fix or utilize those mistakes is what really defines us as woodworkers.
I dont plan on giving all my secrets away but will gladly walk through some basic steps that I hope will help people on their own projects. I have aquired many tools over time that helps these builds move a lot quicker but keep in mind that minimal tools are needed to build a gun. One could get away with a Table saw (preferably 10" or bigger) a router and router table (a table is easy to make if you dont have one), a drill press, and chisels. Take my experience for what its worth, feel free to criticize but be sure that all criticism is constructive for the sake of others.
I will try to keep up with this as much as I can, I am not a very organized person but will do my best, enjoy!
pecs:
60" carbon fiber hybrid with Paduak stock and Aimrite Venom barrel
Partially enclosed composite track
Daryl Wong 3 hole muzzle
Neptonics "reef" trigger mech
Neptonics SS handle frame and remote trigger
60" threaded shaft with slip tip (type has not been decided yet)
First step of the build was deciding on the materials to use. Cost was a factor and since this is my first hybrid my part of the build is pro-bono so to speak... that is unless Xterminator strikes it big in Vegas this week 8)
That being said we chose paduak as the material for the stock. I think I payed around $6-9 a board foot for a nice piece of quarter sawn paduak compared to $28 a board foot for teak. This wood is a dense hardwood with a very rich rose color.
Dont be discouraged by the dark brown color you will find when you look at the wood on the rack. Without a UV inhibitor this wood will darken to a bland brownish purple very quickly but a quick sanding will bring out the original color. Many gun builders, including Phil Herranan, prefer padauk to many other woods due to its rich color, workability, and density. Riffe even started making guns out of Padauk as of recent.
Another reason for our choice was the color will go very nicely with the red kevlar wrap that the Aimrite barrel has.
the next step in this process was laminating the stock (this process is almost exactly what I do for my all wood stocks). Due to the material I had available (4quarter sawn) I was forced to laminate the short stock for this gun. For a stock this short (30" or so) you could get away with a solid piece but good luck finding one big enough. In order to utilize the most out of this wood I chose to use 6 laminates to achieve a thickness of 2.125" wide and 2" tall. After jointing an edge I cut the 6" wide material into 2" strips. I then split them in half on the table saw into 3/8 wide strips.
Notice the grain in the picture below. It is very important to reverse the grain patern with each laminate otherwise laminating is completely usless. This insures that all the natural forces within the wood grain work against each other and cancel each other out rather than with each other and bending or warping the stock.
before gluing I sand the laminates in a cross hatch pattern with 60grit sand paper. This ensures a mechanical bond with the epoxy between laminates. Running wood through a surfacer will often leave a very smooth surface which can lead to disaster when laminating. I then wipe each laminate off with acetone. The effects of this is debatable. I believe it clears each surface of oils, natural resins and dust which might interfere with the bonding process. Others believe that, additionally, the acetone which soaks into the wood grain, will also draw the epoxy deeper into the pours but with the evaporation rate of acetone I think its minimal.
The last step in this process is epoxy and clamping. I use Fiberglass Hawaii's 2 part epoxy which is compatible with West Systems products. Due to the deep voids in this grain I have added microfibers to the mix to insure the epoxy fills all these voids before curing. I use a disposable brush and coat each side of the laminate thoroughly with epoxy. When clamping it is important to clamp to a straight surface and use as many clamps (preferably the same type) with even pressure throughout. It is also important to not over tighten the clamps. You want to tighten until you see the epoxy being squeezed out of the joint, too much will starve the joint of epoxy and weaken it.
Once the stock has been clamped it is important to leave it in the clamps for 24 hours or more. You want to ensure the epoxy has fully cured before continuing with the build. With my all wood stocks I will take them out of the clamps and often let them hang for up to a month. this insures that any additional movement can be fixed before the track is cut and the gun is shaped. If you cut the track too soon and the gun bows on you often times you are SOL so take your time.
Since this is such a short piece and there are so many laminates curing should not be an issue. I will leave it in the clamps for a while and probably start the next step by the end of the week.