Sunday, January 24, 2010

MOLD CONSTRUCTION!!!!!!!!!!! MWAHHHAHHAA!






All,

Today, our molds began to rise from a pile of plywood and dimensional lumber. For those that have been unsure of our molding system, or still are unsure, the keep posted to here, and COEM TO THE LAB!!!!

Our ribs/framing consists of 1/2'' Plywood cut by our local Woodshop, and aligned on a center keel and braced into place. This will be followed by our new fiberglass planking material, and several layers of chopped strand fiberglass.

These are only the beginnings, but we've only got 2 weeks to get 'er done, so come on down and jump right in! You could end up using a air-powered staple gun!

Tuesday, January 19, 2010

Wednesday, September 9, 2009

A Late Conclusion and Farewell

Sorry for the extraordinary delay, I had not wanted to come to terms with the obvious. Not necessarily the fact that we lost at Regionals in a catastrophe so large it proves the existence of a higher power, but that my time with canoe was over.

2009 Drexel University Concrete Canoe's Phanatic failed at Regionals in punching shear. The Phanatic was in beautiful form through Saturday's display, only lightly smelling of sealant in true Drexel fashion. Sunday morning seemed to be going according to plan with a successful swamp test, but loading our first and lightest racers for the Female endurance race, a knee found a weak spot in the hull and we lost about a 4" diameter hole. A thin spot in the hull, surrounded by a thick spot, and without primary reinforcement could not hold up to the stresses of racing. We had toyed around with the difficulty of putting reinforcement in the hull, knowing full well it had it's advantages, we could not feasibly do it with our dual mold design.

In good spirit, we all got the boat out of the water and duct taped it until she was seaworthy again. Then we went and did quite well in the races, knowing that our competition was coming to an end. By the end or races, it was quite apparent that we may even take first place with the deduction for using duct tape, seeing that we won most of the races and having assumed we took best report and presentation. However the judges decided to disqualify us from Final Product seeing that we did not finish the final race due to the boat taking on some water. The judges took a very literal definition of the rule, and The University of Pittsburgh-Johnstown pressured the judges into the DQ. We had intended on passing the Nationals invitation to the runner up team, but that does not mean we were not the best boat and team at the competition. UPJ directly involved themselves with the judges and that was wrong. Their boat had an illegal mix, and if we had chosen to go through their fine print, we could have had them DQ'd as well. As it stands, they went to the National Competition and finished in last with the other disqualified teams. While it is obvious I am bitter about UPJ's move, we were not going to Nationals with a broken boat, and having UPJ win Regionals was nearly our choice.

There's plenty of photos on facebook I hope to post once I get my home computer operational. But for the now I'd like to take the opportunity to thank everyone that was involved in this project, most notably my partners: Pat Perhosky, Alan Fody, my crew: Mo, Nick, Ed, Aga, Marie, Alisha, Chris, Megan, Corey, my alumni support: Dave Morgan, Kyle Rutherford, Norman Jones My advisors: The Canoe Wizard, Doc Martin, Dave Cliffel, Dr. Cheng, Dr. Hsuan, My supporters: See (rear of tshirt), Dean Guiceri for throwin a few bones, and last but not least, my girlfriend Kelly for putting up with me reeking of concrete 6 outta 7 days of the week.. I'll have to write a legitimate thank you post at another time because many of these people did such a seriously great job.

In closing, I loved this project, I loved it more than school. Which is why I'm not in grad school. I jest, I wanted to work after my bachelors and that's exactly what I'm doing. Pretty damn well too, if I may say so, thanks to the Project Management I've learned from this painful experiment. I don't take anything back, and my only regret is not finding a means of getting a sturdy reinforcement in the Hull.

As a final note, all you male engineering students who are lacking love due to the Drexel M/F ratio, the concrete canoe team does wonders...

Sunday, April 12, 2009

Recruitment Video

Here's a compilation of footage Norman Jones put together from last year to get the hype up for this year. It's getting rave reviews throughout the interweb.

Wednesday, April 1, 2009

Ladies and Gentlemen, meet the Phanatic

She's still the female mold at the moment, but she's a beautiful shade of gray.


She also double's as a bath tub, curing towards her ultimate strength.


Now that we've got a boat, we can play around with arts n crafts... Here's some dyed concrete.
I feel funny, strange even, like I'm gaining some superhuman strength...
Pat always eats anything that resembles ice cream.
Chris is Phanatic phace artist...

More to come, just wanted to let the world know that we have arrived.

Saturday, March 21, 2009

Pour, Take 2.

This past Thursday we attempted our second try at pouring our concrete canoe. The first one was a fair practice run, but ended up in casting failure. When we removed the male plug from the 2 day strong concrete, we found the concrete had made it's way past the polyurethane coats. It bonded with the plaster and took up some of the fiberglass cloth that held the original balsa wood backbone of the mold together. Having planned to make more than 1 boat, we quickly made the executive decision of laying an extremely smooth membrane in the female, and wrapping the male with a lightweight plastic. The membrane had worked for teams in the past using a hand placing method, and the lightweight plastic had worked in our male mold test earlier in the year. It was no easy task laying the membrane in, we began to feel like rubber tailors. However, the possibility of an extremely smooth boat right out of the mold outweighs the risk of seems. For those who want to know more about the membrane laying process, leave a comment. I will not give away too many secrets unless I know you're playing for Drexel.

After upgrading our molds, we mixed up our proven best concrete mix and went at it again.

Here's the female mold, black with the membrane, some steel mesh (magically) suspended on the sides, plywood rib cage, and 4 alignment poles.


Here's the wrap of the male mold looking quite nice, notice the folds strictly at the end.

Here's an example of the alignment pole, the pole itself for X & Y control, the wood block there for Z control.

Here's the steel mesh we used as our primary reinforcement. Last year's epic cracking led to our creative ways of smuggling reinforcement.

Here's Mo alongside all our buckets set up for half cubic foot mixes.

The male mold eagerly waits alongside the old champs,
Pat working the drill while Chris steadies the bucket and Marie adds our cementitious material blend.

Coming along nicely.

Myself working the drill with Alisha adding silica fume, Mo handling the water, and Megan learning the way.

I used to have nice boots.

In go some fibers...

After we made enough, we poured em all in and spread it out.

In comes the male mold...
Onto the poles...


Adding the weight to the push in the male,
The steel plates are around 80lbs, the buckets 40-70lbs.

The front tip,
The back tip,
Pour complete!

We'll be taking out the male plug Saturday at Noon. It will surely be an exciting afternoon.

Greg

Monday, March 2, 2009

Week 9: Finishing Job Assignments

While we didn't meet our Week 8 goal of casting, we accomplished some very necessary corrections to the casting system. Over the next couple days we'll have some quick catch up work shooting for the new goal of Tuesday Night's Pour & Pizza.

As we've approached the final stretch of construction, I've gotten a pretty good sense of whose been working with what. I'm going to assign some of you that are regulars jobs that need to be completed throughout the next month. Those of you that are not named directly on to a specific task, need to be aware of which ones will require more hands or minds to complete, ie. the mold alignment and rebar installation. I feel as though having random appearances with often little jobs leads to idle hands. This specialization will steady your hands with specific fields and train you to step up and lead it next year. Without further ado,

Mold Alignment Goal: Finished by Monday evening
Ed edwin.s.williams@gmail.com
Greg gs592@drexel.edu
Nick nicholassimmons27@gmail.com
Mo mm4522@drexel.edu
Ali M. email missing, Mo Pass word on
Chris R. dieselprep@gmail.com
Hands will be needed Monday/Tuesday

Reinforcement Installation
Goal: Finished by Tuesday afternoon, Arrangement recommendations after first pour
Pat P jjp462@drexel.edu
Alan alan.c.fody@drexel.edu
Ali R. arehemtulla@gmail.com
Alisha alisha.strayer@gmail.com
Dave F. dmf482@drexel.edu
Hands will be needed Monday/Tuesday

Tshirts Goal: Ordered by Friday
Marie mbl33@drexel.edu
Pat P jjp462@drexel.edu
Any others with interest or experience, email them.

Structural Research & Concrete Testing
Goal: Something report worthy by Wednesday
Mo mm4522@drexel.edu
Alan alan.c.fody@drexel.edu
Alisha alisha.strayer@gmail.com
Any others interested, email Mo/Alan

Mix Decision and Testing
Goal: Best mix selection, adaptions. Material Inventory.
Pat P jjp462@drexel.edu
Alan alan.c.fody@drexel.edu
Ange amc325@drexel.edu
Another underclassmen participant recommended.

Hours & Dollars Accounting Goal: Something report worthy by Wednesday
Pat P jjp462@drexel.edu
Aga ays28@drexel.edu
Marie mbl33@drexel.edu
Ali R arehemtulla@gmail.com
Others good with quick math, join in.

Design Report

Pat P. jjp462@drexel.edu
Greg gs592@drexel.edu
Alan alan.c.fody@drexel.edu
Ali R. arehemtulla@gmail.com
Nick (HISTORIAN!!!1!eleven!!) nicholassimmons27@gmail.com
Alisha alisha.strayer@gmail.com
Marie mbl33@drexel.edu
Anyone good with words/creativity jump in asap.

There are many names on the email list, that are not found on this list. You are all welcome to join in on a task, ask those involved.

Everyone on the list is encouraged to work out times with each other to meet deadlines. The construction jobs atop the list are obviously a must over the next 2 days. I will be in the lab for nearly all the next 48 hours.

This is a living system, if you're schedule doesn't line up, ask someone to switch jobs with you. However, underclassmen can only switch with underclassmen and seniors can only switch with seniors. Knowledge must be passed on. If you need advice on a task, ask anyone involved and if you're in something deep, ask a professor or alumni.

Update Through Week 8 in Picture Form

Here's a pile of photos from having the lab camera cleared out. The dates are still about a month behind, not from on however, thanks Nick.

Here's a few from the smale scale pour we did on the 8' section we built a while pack with an old foam female.
Cutting the reinforcement,
Pressing the male into the female,
160lbs of calm compression,
Nearly a finished system,


Here's our recent most glorious spread test,
34" of consistent self consolidating concrete baby.
Stronggggg light cylinders,
Power tools and pool noodles,
The Mars Volta stopped by the lab to help out with the ends of the mold,


Do this for 4 hours and you realize you better get a sweet boat out of it.
Good crowd Saturday,


Thats all for now, more to come as we go.
Greg

Sunday, February 8, 2009

Male Mold Update!

How fitting that after a few weeks without updates, I post one in the wee hours of Saturday night/Sunday morning. That is whats left of my spare time.

Those that have taken part the past couple weeks can tell you of the intense work going on down in the labs.

It sure as hell feels good to drive a nail again. - Ali Majd

He about perfectly summed up how I feel about the last few weeks of hands-on mold casting. However my hesitance to update some specifics of it comes in with the fact that we have a secret weapon. I will not reveal it's identity online, but a trip to the lab could lead to me bragging about it.

Here's Pat and Corey cutting up some chopped fiberglass to use in the mold.

We laid down sheets of it within our secret mold material and then paper-mache style glued on the fiberglass sheets. We take fume safety seriously.



Here's Pat and I mixing up some resin. Pat has become the master chef of laminating resin cooking.
This is our male mold all glass in and with some temporary cross bracing so it dried in the perfect shape of the female foam mold. Seeing as how the foam mold cost thousands, we hope to keep it in perfect shape for future canoe molds. Not to say our cast fiberglass molds won't stand the test of time.


Here I am readying the drill for some quick diaphragm installation prior to glassing them over.
Here's the test fit, got some warped beams in there but that's half the battle with using excess wood from years past.

Aga glassing the ribs over with our woven fiberglass. I think he won MVP that night for most fiberglass strips laid in an hour.
Here's Ed, our carpentry mastermind laying down some good tack for the structural beams to stick in for the while.

Here's the Monday night group wrapping up a few good hours work.

If you're wondering as to the date on the photos, it's wrong. Most of these are from the past 2 weeks, I haven't rigged up Nick's old camera correctly yet.

Next post, I'll have the link up for our recruitment video. It may not actually recruit anyone, but at least its awesome and hilarious. I'd like to thank Marie for taking so many of these pictures, and Nick for donating a camera.

Greg