Alternative filling material

[dbanner]

I have had success using a mixture of sanding sealer and plastafilla(cellulose based). It's very cheap and most importantly it's waterproof and light. Then I use truck bed liner to coat the surface for extra toughness.

[dfbowers]

Looking good Don! how it perform the epoxy?

The shells I filled seemes to still be working just fine. Anyone ever try a graphite filler for shielding? I read elsewhere that a 13% graphite mix by weight might work for electrostatic shielding.

[ripsdevala]

I fill mix of wood dust+super glue+resin on top layer, very light

[dfbowers]

I just fill 1/2 shells (top part only),and leave the potting compound as the bottom.

[Mudflap]

I just finished my first coil with Max MCR black A/B https://theepoxyexperts.com/product-...-mcr-black-ab/ For the price it's almost unbeatable. I can fill 5 or 6 large shells with a 48 Oz bottle and it sets hard as nails.. and at least 5x cheaper than MG chemicals 832b ☺.

Do you install the bottom coil form or just leave the potting as the coil bottom?

[SVEN1]

Hey Don, figured you might like that epoxy, so easy to work with, can be messy as its so thin. I have been using it for several years now. Nice thing about the epoxy is "No air Bubbles".
Now the filler material in the black epoxy will need to be stirred back into solution. Other thing I do, before mixing the hardener, is fill a bucket up about 5" with hot water, set the epoxy bottle in it for about 10 minutes or so, especially if it was stored in a cold area or has thickened too much. You can't beat the price. And there is virtually no odor and the slight odor it has is not offensive.

[ionut_mtb]

I just finished my first coil with Max MCR black A/B https://theepoxyexperts.com/product-...-mcr-black-ab/ For the price it's almost unbeatable. I can fill 5 or 6 large shells with a 48 Oz bottle and it sets hard as nails.. and at least 5x cheaper than MG chemicals 832b ☺.

Looking good Don! how it perform the epoxy?

[dfbowers]

I just finished my first coil with Max MCR black A/B https://theepoxyexperts.com/product-...-mcr-black-ab/ For the price it's almost unbeatable. I can fill 5 or 6 large shells with a 48 Oz bottle and it sets hard as nails.. and at least 5x cheaper than MG chemicals 832b ☺.

[homefire]

Vermiculite loves water. You would have to insure it was Dry first.

https://www.cambridge.org/core/journals/journal-of-materials-research/article/hydration-phase-transitions-and-magnetic-properties-of-vermiculite-intercalation-compounds/026DFEEEB391119464504E83C5DE9F35

[BKY1337]

Are you sure? Vermiculite is a mineral.

[WM6]

To get more stronger and lite epoxy filling, you ca use vermiculite (construction or gardening additive)..

[BKY1337]

I tried it, it works.

The pieces doesnt float if you use enough from it. And you can make more layers to be sure.
The styrodur doesnt dissolve in the resin and its light. I also used glassfibers at the outter arms.

[WM6]

You ca try to fill coil housing by Pur-Pen (polyurethane construction filler/adhesive in spray dose),
cut it under inner housing edge to let some space for final epoxy layer (better armored by fabric).

[Goaty]

It may be worth a try using it as a filler in resin but there could be problems with the beads floating to the surface.
Also, if the polystyrene were powdered, the resin could be absorbed into the voids, greatly reducing the filler effect.
It can only be used with epoxy resin as the beads will quickly dissolve in polyester.
I agree with WM6 about the need for a composite surface layer but this could end up rather bumpy if laid straight over the bead/resin mix which would be difficult to sand smooth.

[WM6]

What is styrodur? I'm assuming it's expanded polystyrene.

Yes, Styrodur is brand name of expanded polystyrene.

You do do not need to pulverize it, cause it is available in small cheap balls too (outer epoxy layer should be armored by some sort of fabric):

http://www.ebay.co.uk/p/Styrofoam-Polystyrene-Filler-Foam-Beads-Random-Colors-Assorted-Balls-Crafts-Small/2113259990