Attempt at home made Micarta scales Flop

Well i tried to make my own micarta scales with colored construction paper and it didn't quite come out like the youtube videos i have watched so maybe you guys can help me out.

I used different colors and put them together using fiberglass resin and hardener.

When i clamped them together for a 24 hour time frame i took them off they seemed ok.

When i sawed them in half it seemed that the resin did not get in to all of the layers well so the paper came apart at the middle.

My guess is that i clamped them to tight and most of the resin seeped out.

Now i know i really clamped them tight on my vise grip(really tight)

Could that have been the problem or should i attempt some with fabric and see what happens?

Thank you for any advice you may have as i really want to get at least one straight with my own micarta scales done.

I have never made micarta ,but if it is only failing in a few places couldn't you re work it?

Good luck
Jonathan

the term you are looking for is called "wet out" and in paper it can be a reall problem in faster setting epoxy (it does not have time to soak inbefore it starts to set
fabric seems to work better but you need to be carful about the type of fabric vs resin (some kind of dont excepe the resin

I tried making some paper micarta once and it turned out exactly the same. It started peeling apart once I tried to cut it. Haven't tried it since, but been meaning to try fabric. Figured I would keep an eye on this post to learn something if I can.

This is going to be a learning thread for a few of us I guess. I too have watched the videos, however have not come to this on my project list yet. It makes perfect sense the if the resin set to quickly it wont have time to absorb, also there are different viscosity resins. I know it is possible to over clamp and starve out a glue joint as well. So what I'm trying to say is there could be multiple factors. It will be good when someone with experience comments.

Wet-out each sheet of paper before placing it down. Be VERY liberal with the resin. Pressure won't squeeze it away from the paper, in fact you likely had an air bubble that couldn't get squeezed out. I work in composites and we face this a lot. More pressure will actually help as long as it is evenly distributed! The key is to add more resin to each sheet and set a wet sheet on top of a wet sheet. Think about trying to squeeze out air-bubbles maybe we a squeegee (or credit card) before you move on to the next sheet! Fabric helps as the air cannot remain as trapped. it will force itself through the layers. Wet paper simply has to go out between the layers! I hope this helps!

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Originally Posted by carpedm

Wet-out each sheet of paper before placing it down. Be VERY liberal with the resin. Pressure won't squeeze it away from the paper, in fact you likely had an air bubble that couldn't get squeezed out. I work in composites and we face this a lot. More pressure will actually help as long as it is evenly distributed! The key is to add more resin to each sheet and set a wet sheet on top of a wet sheet. Think about trying to squeeze out air-bubbles maybe we a squeegee (or credit card) before you move on to the next sheet! Fabric helps as the air cannot remain as trapped. it will force itself through the layers. Wet paper simply has to go out between the layers! I hope this helps!

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This is what i am going to try next time a try paper.
One thing is true,i used a brush to apply the resin like paint on the paper and i know now that i only put a little bit which seems to be the problem as you said.

I then tried one with material from an old shirt and put more resin this time(by hand and rubbed it in the fabric with much more quantity).

Now this one came out great.

I have rough cut it out with a coping saw and getting ready to sand it down.

When i finish it i will post some pics.

The good thing is that this micarta is pretty simple to cut out with no major power tools.

Coping saw works pretty good.

To be continued........

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Originally Posted by traps38

This is what i am going to try next time a try paper.
One thing is true,i used a brush to apply the resin like paint on the paper and i know now that i only put a little bit which seems to be the problem as you said.

I then tried one with material from an old shirt and put more resin this time(by hand and rubbed it in the fabric with much more quantity).

Now this one came out great.

I have rough cut it out with a coping saw and getting ready to sand it down.

When i finish it i will post some pics.

The good thing is that this micarta is pretty simple to cut out with no major power tools.

Coping saw works pretty good.

To be continued........

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This is what i am up to till now.

Attachment 132917Attachment 132918Attachment 132919Attachment 132920

Took the material i cut out.
Layers of it with resin and then clamped over night.
And till here now.

Make sure that your paper is wet on both sides from the epoxy.

I make it like this way:
I use printing paper ,white& color paper
Make sure you have a flat onderground (wood or steel plate)
Then i lay a plastic garbage bag on that onderground than epoxy,a layerpaper,epoxy ect ect until you have the correct thickness. Make sure you spread the epoxy enough about your paper.
Then again some garbage bag plastic a upperlay of wood or steel plate or anything else you use.
Clamp for a day and you are ready to go. (sometimes is 24 u not not enough, epoxy dry the best whit 18 degree)
Good luck and have fun

This is all really great stuff, thanks for posting everyone!

So epoxy won't stick to the plastic bag or am I missing something?

I have used more than once those plastic bags. Epoxy dont stick on those bags.
Some people use backing paper but imo those bags are easier to remove from the material.

Note: make dure that the plastic lays flat otherwise you get not a flat surface and you must sand that out.

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Originally Posted by traps38

This is what i am up to till now.

Attachment 132917Attachment 132918Attachment 132919Attachment 132920

Took the material i cut out.
Layers of it with resin and then clamped over night.
And till here now.

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OK, i just finished sanding out my rough scales on 120 grit sander and this is what the scales look like now.

Attachment 133145Attachment 133146Attachment 133147Attachment 133148

I don't think they look that bad.

Now i have to hand sand them till 2000 grit and see what they look like then.

To be continued.....

Love the color pattern.

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Originally Posted by kalerolf

Love the color pattern.

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I agree. Those are going to look nice when done. Good luck and keeps us posted.

Well,here is my end product.

Don't forget this is my first time making Micarta.

Now there a lot of tweeks i need to figure out but i think this is something i am going to try and figure out and have fun with.

Attachment 133269Attachment 133270Attachment 133271Attachment 133272

Just a couple of questions if anyone knows.

Is there anything you can put on Micarta scales to make them shiny and what happens if you wet the scales now?

You can't really tell in the picture but there is some brown gold color between the design of the blue and white which i figure is the resin showing.

Is there a way for this not to show or just use dark colors next time?

Please be kind with your remarks and i will for sure do another one soon.

Hope you enjoyed my process.

I'm really intrigued from top to bottom. How do the scales feel in your hands? I'm huge on textures and following the pictures from start to finish has really piqued my interest. You did a fine job on that, sir.

I like the look of them. The white marks look like they are floating over the other colors like a cloudy sky. Never worked with micarta yet since I couldn't get it to set right, but I would think that sanding to a high grit and polishing would make them shine. Maybe someone with more experience will chime in. Either way great job, I like them.

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Originally Posted by Jonah

I'm really intrigued from top to bottom. How do the scales feel in your hands? I'm huge on textures and following the pictures from start to finish has really piqued my interest. You did a fine job on that, sir.

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Thank you.
They feel solid and have a good weight to them.
They did get very smooth from the sanding and feel great.
Now i have them in my "Honing garage" waiting for them to get honed.
NEXTTTTTTTTTTTT......

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Originally Posted by traps38

Thank you.
They feel solid and have a good weight to them.
They did get very smooth from the sanding and feel great.
Now i have them in my "Honing garage" waiting for them to get honed.
NEXTTTTTTTTTTTT......

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That's really neat. I'm definitely a "learn by touch" kind of guy. If I'm in a store and I see something new, most times I have to touch it to experience the tactile response. I keep looking at those scales and I am absolutely intrigued. Now I have to make some myself, thanks for the inspiration :p

As far as shiny, I'm wondering if you could use CA glue or Epoxy to put a layer down on top of the finished scales for cutting/polishing....

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Originally Posted by Kalloran

As far as shiny, I'm wondering if you could use CA glue or Epoxy to put a layer down on top of the finished scales for cutting/polishing....

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The micarta I've made I've finished with ca glue. It works well but with cloth you have to make sure to put enough ca on the scales or some fibers will show through and get dirty and discolor.

The yellow color you said about is from using fiberglass resin. If you used bondo or 3m brand you will definately see yellow tints. Another brand to try it envirotex. It's not super expensive and you can buy it at Michael's craft stores. It dries very clear.

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Originally Posted by meleii

The micarta I've made I've finished with ca glue. It works well but with cloth you have to make sure to put enough ca on the scales or some fibers will show through and get dirty and discolor.

The yellow color you said about is from using fiberglass resin. If you used bondo or 3m brand you will definately see yellow tints. Another brand to try it envirotex. It's not super expensive and you can buy it at Michael's craft stores. It dries very clear.

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Thank you for the help.
I have to see if i can get this envirotex here in Canada.
I guess i should use dark material if i don't want this yellowish tint to show?

As far as the shiny thing, you can use some marine polish.
Use a dremel on very low speed

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Originally Posted by kalerolf

As far as the shiny thing, you can use some marine polish.
Use a dremel on very low speed

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Thank you.
Where would you get this marine polish?

Here in Holland we have some onlineshops that are specialist in polish stuff. I use most of the time Autosol Marine shine.

Think the www is the place to look, or a local shop that sells polish.

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Originally Posted by kalerolf

I have used more than once those plastic bags. Epoxy dont stick on those bags.
Some people use backing paper but imo those bags are easier to remove from the material.

Note: make dure that the plastic lays flat otherwise you get not a flat surface and you must sand that out.

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The wax paper comes of the micarta in pieces all the time and tears everywhere.
Is there a trick that will make the wax paper come off easier or should i try the plastic bag next time or buy better wax paper?

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Originally Posted by traps38

The wax paper comes of the micarta in pieces all the time and tears everywhere.
Is there a trick that will make the wax paper come off easier or should i try the plastic bag next time or buy better wax paper?

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Metal sheets with mold release work very well!

I use a stainless steel plate on one side and a 2x6 wrapped in wax paper for the other side. To get it off of the stainless I have to give a pretty good tug but it releases easily enough.

Gave another attempt at this micarta thing.

This time i used blue denim jeans and black ones.

Attachment 134379

I then proceeded my usual with resin and clamping,then cutting out and shaping and sanding.

This is what i came out with.

Attachment 134380Attachment 134381Attachment 134382Attachment 134383

Pinned the wedge part now just need to add the blade.