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Coroplast is made of Polypropylene which is great for many uses due to the fact that it is resistant to chemicals; unfortunately the same properties make it difficult to bond using chemical bonding agents.
How about using either good old zip ties, duct tape or pop rivets:wink:
You can locate a professional foam supplier with a cnc machine for cutting foam.Lots of these are unemployed in Detroit now.We have one in Sacramento,Ca.
Then locate someone who uses a www.nextengine.com scanner and scan the vessel in sections then use that file for the cnc machining of the foam material.This would of course be the negative of the vessel and in two pieces with the hinged lid being only 25% of the overall heigth.Then have a custom pickup bed spray-lining company spray the two pieces,inside and out, with the durable rubber coating and you have a very long-lasting,water-proof container.You can finish the inside with a sprayable fuzzy material or simply spray 3-M rubber cement and dust it with your own fuzzy preference.I have made other products using this method with great results.
Seeing as my model (prototype from Merriman) didn't have a box, I decided to make one. I had some oak slats from a concertina door laying around, and they looked perfect for the job.
I wanted to make it so the box became the display stand, and made the base a two tier affair. This allowed the box lid to fit exactly over the base.
A few bits of pink foam carved to fit, then glued into place with a dab of RTV, will hold the boat in position.
I intend to use two screws on the ends, screwing the lid onto the base.
Here is another shot of the finished box. (No varnish applied yet) I've placed a one cent coin and a Quarter alongside to give you a perspective of how small this boat is.
I want to briefly discuss the problems I see with making boxes for submarines. My main concern is 'kinetic energy' (the energy of motion) contained within the actual model when the model and box are set in motion.
Lets do some homework first. http://en.wikipedia.org/wiki/Kinetic_energy
When we place a submarine in it's box, we now have TWO objects that are put into motion when they are moved. If the outer object (the box) suddenly stops, the inner object (the sub) still has it's kinetic energy and, unless rigidly secured to the box, will carry on until it crashes into the end of the box.
The straps, foam, pillars and screws holding that boat in place have to be strong enough to withstand the entire weight of the boat traveling at speed. The box has to also have sufficient padding to absorb the weight and or spread the load of the model entirely. Strapping a boat in place with a few bits of foam will result in the kinetic energy being built up in the boat, wrenching it free and crashing it headlong into the box end.
You could think that wrapping the Submarine box in padding and placing it inside a cardboard box would solve all the problems, but if that sub were loosely fitting and had weak straps, when the box stopped suddenly (hit the ground etc.) the submarine would move inside the box and be damaged.
To make the model safe, it has to be thoroughly strapped in to ensure it does not slide about; having a sloppy fit inside its box is probably the worst thing you could do to your boat.
I am talking to a box manufacturer who can make a custom box from plywood, to our spec. as long as I order in quantity.
The problem is that we have so many sizes of boat. The company suggested placing a foam insert in an oversized box, that has 'cookie cutter' removable parts, so that a variety of models can use the same outer box.
In the case of the smaller models, perhaps two boats could fit into one box ie: a trumpeter Kilo and Seawolf could fit inside on larger box, or maybe a Revell Gato could replace those two?
So, what sized boxes do you think would be viable?
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