First Graphite X-6 Chassis Is Produced!!!!
   

We've written about Keith Julius, and you've heard him on a podcast: Here's Keith working on the design of the battery strap.

Ejector side of the main mold. "Core pins" protrude to make holes in the shock tower. A "loose piece" goes in the cavity to make the bottom part of the tower.
 

The "loose piece." It's called that because it comes out of the mold every time a part is made. The four core pins on top make the ball stud holes.

One of the smaller C.N.C. Mills at Advantage Mold ready to begin work on the M.U.D. insert mold that will make the transmission case.
 

The smaller machine has a far simpler control panel than the big one you've seen in earlier stories. (Sorry about the blurry photo. We hope you get the idea.)

This is what your R/C cars are made of. These are pellets of "graphite" ready to go into the dryer. They're dried for several hours to eliminate all moisture before going into the press.
 

Advantage Mold's 230 ton press. Todd is setting it up to run. The dried pellets go in the silver bin at the top right. Those are the very latest high-tech pellet containers next to the bin.

Todd checks the press controls.
 

The ejector side has been mounted in the press. The blue springs push the ejector pins back after they have come forward to push the part out of the mold. The "loose piece" still is not in its place.

Now the cover side has been mounted.
 

Todd has attached the water lines to the cover and is working on attaching them to the ejector. Water is warmed to about 175 degrees and circulated through the mold to maintain a constant temperature. A warm mold helps the plastic flow, but as the mold heats up the temperature is maintained to make sure it's not too hot so the carbon fibers break down. Also, steady temperature assures repeatability.

The very first shock tower and nose piece. A valve in the mold was closed so it just made these two parts and not a chassis. Note the left-over Prussian blue on the shock tower. That, of course, will be gone soon.
   

Other side of the very first shock tower and nose piece. Adjustments will be made to several core pins and ejector pins to make the holes in the parts just right and make the smallest possible ejector marks.

Designer Keith Julius is happy with the first parts.
   

The mold is being pushed together with 230 tons of hydraulic pressure. The press won't work unless the sliding door with a clear cover is closed to keep the operator's fingers out. That's Chazz's reflection taking the picture.

The first one. Oops -- not enough plastic. Turn it up, Todd!
   

Very close, the the reservoir's still not full. Turn it up just a bit more, Todd!

Much better! This is the third "shot." Plastic comes in from the chassis rear (note runner) and exits at the front. The run-off reservoir ensures perfect mold fill in the nose and allows the carbon fibers in the plastic to allign correctly.
   

And here it is! The first finished chassis. Still a few very minor imperfections to work out, but excellent for the first one.

Nose piece fits perfect. You could bolt a B4 front end right on!
   

Shock tower fits correctly too.

Shock tower from the rear.
   

Well done, Keith!

Todd and Keith check their work. Nice job, guys!
 
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