What material could I use to make this?

Gerhardt

Gerhardt

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Gerhardt
I have a ZTR that discharges grass clippings to the side. Unfortunately, they do not make an OCDC (operator controlled discharge chute) for my model so I'd like to make one myself.

I need to contruct something to cover a small portion of the top of the deck and about 18" of the side. Picture about 1/8th of a large plastic garbage can lid that has a 5" lip. There would be some pressure, but not a lot, on it as it is raised and lowered as needed.

I don't have the means to form this out of metal or plastic. Would fiberglas resin over a molded skin be strong enough? FiberFix?
 
Gerhardt said:
Would fiberglas resin over a molded skin be strong enough? FiberFix?
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two layers of glass will hold up the world, three will hold the solar system -

obviously a joke but two layers of glass is pretty tough and will undoubtedly handle grass clippings
 
Gerhardt said:
I have a ZTR that discharges grass clippings to the side. Unfortunately, they do not make an OCDC (operator controlled discharge chute) for my model so I'd like to make one myself.

I need to contruct something to cover a small portion of the top of the deck and about 18" of the side. Picture about 1/8th of a large plastic garbage can lid that has a 5" lip. There would be some pressure, but not a lot, on it as it is raised and lowered as needed.

I don't have the means to form this out of metal or plastic. Would fiberglas resin over a molded skin be strong enough? FiberFix?
Click to expand...


Pink foam board like this to make the mold/plug http://www.homedepot.com/p/Owens-Co...ulation-Sheathing-52DD/202085962?N=5yc1vZbaxx

Add lots of microballons to small batch of mixed epoxy resin to glue sheets of foam together. Sand the foam assembly to shape.

Cover the outside of the foam with clear packing tape or more microballoon slurry.

Apply release like hair spray, petroleum jelly, wax to the mold.

3 layers of 7ish ounce plain weave glass.

Epoxy resins won't eat the pink foam but I think polyester resins will.
 
bnt83 said:
Pink foam board like this to make the mold/plug http://www.homedepot.com/p/Owens-Co...ulation-Sheathing-52DD/202085962?N=5yc1vZbaxx

Add lots of microballons to small batch of mixed epoxy resin to glue sheets of foam together. Sand the foam assembly to shape.

Cover the outside of the foam with clear packing tape or more microballoon slurry.

Apply release like hair spray, petroleum jelly, wax to the mold.

3 layers of 7ish ounce plain weave glass.

Epoxy resins won't eat the pink foam but I think polyester resins will.
Click to expand...

Just thinking about erosion, should a strip of aluminum sheet be placed on the mold before laying the glass?
 
You're making this look like an easy and fun project. Thanks a lot. I appreciate the help.
 
Obviously we have failed you. It should look like a challenging and difficult project.
 
I tried to complicate it by adding an anti-erosion strip...
 
I just repaired my grass catcher chute with bidi FG and some epoxy resin. The repl chute piece was $82, I spent about $12 on FG materials and a few hours of prep, layup and grinding sanding some defects off. It will last until I'm in the ground.
 
Naaa. A few supplies and organization make if fun.

The clear tubs are (left to right)

Microballoons, CarboSil and Cotton Flock



 
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Probably the biggest learning curve I experienced (Im no expert but hear me out) is getting a "feel" for the resin. I was scared to use FAST hardener as it seemed like I was way too slow and then the resin would poorly wet-out the fabric. It turns out that the resin was just plain too cold. I have been using FAST exclusively for a while now but have two 250 watt heatlamps on standby to keep everything a little warmer while wetting stuff out.

After I get everything wet out well I remove the heat lamps and hang around for an hour to let the resin gel, then reapply the heat. If you don't remove the heat and just go balls to the walls with it the resin will literally run right out of the area.
 
I don't have a clear mental picture of how you're going to attach it to the deck. If you're going to use bolts, a reinforcing aluminum strip might be a good thought...
 
Chip Sylverne said:
I don't have a clear mental picture of how you're going to attach it to the deck. If you're going to use bolts, a reinforcing aluminum strip might be a good thought...
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That's the spirit - make complicated and messy. :rofl:
 
Its a lawn mower, pop rivets, bolts, screws, double-stick tape :D
 
Clark1961 said:
That's the spirit - make complicated and messy. :rofl:
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I built a kayak out of fiberglass many moons ago in high school. Throwing a sheet of aluminum in the layup ain't no big deal. And with two sheets of fiber, if he rivets it the first time he hits a rock, tree, shrub, curb or he like with it, without some reinforcement it's breaking off.

Of course, then he can fix it by glassing in a sheet of aluminum....
 
For supplies, I usually use Industrial Arts Supply (http://iasco-tesco.com/) They mainly sell to high school industrial arts teachers and are very happy selling in small quantities. They'll also have everything you need. The web site is pretty klunky but you can download their catalog. I haven't done much with them lately but their prices always seemed to be pretty reasonable too.

Re pink/polystyrene foam, polyester resin will definitely dissolve it. Polyester will not dissolve polyurethane foam. Polyester is really stinky stuff -- For sure don't use it in the house. Epoxy is more expensive but for a small project I don't think that is a big consideration.

Note that the microballoons are not used in the final part, just in making the plug. You should also get some type of roller (IASCO catalog page 79). The objective is to use as little resin as possible; just enough to wet the glass and make it stick together. A roller helps force the resin into the cloth.

As far as reinforcing, if the design permits I might just glass a piece of 1/4" or thinner plywood in there. That will add much more strength than any kind of sheet metal.
 
nothing some left over galvanized sheet metal, pop rivets, bailing wire, duct tape, and chewing gum couldn't fix.....:D
 
Get some hvac duct from home depot. Its cheap and easy to work with.
 
I think fiberglassing this projects is more trouble than benefit. Why not just get some thin sheet metal, some tin snips, and some rivets? I feel like a spring/piano hinge and the sheet metal should make this a quick/easy project without having to worry about layup and creating molds/reinforcement.
 
yup.....:D

maxresdefault.jpg


bagger2.jpg
 
SoonerAviator said:
Why not just get some thin sheet metal, some tin snips, and some rivets?
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This doesn't need to be professional-grade, but it does have to have curb-appeal. i.e. look nice from a short distance. I've found the fiberglas resin and I have the mold already done. I'd already considered the reinforcements.
 
I was going to recommend kydex. Easy to form and work with
 
way overthinking the problem. Get a mulching blade, leave the clippings where they need to be, the place they came from!
My life is a lot easier since I did this. Try it...you will like.
 
Let'sgoflying! said:
way overthinking the problem. Get a mulching blade, leave the clippings where they need to be, the place they came from!
My life is a lot easier since I did this. Try it...you will like.
Click to expand...

I'm running G5 blades and they're great. The mower isn't meant to be a mulching mower so there is no mulching kit for it - it only side discharges. What I'm making is an OCDC so that when I get near areas where I don't want to blow grass I can close the deck for a short period of time.
 
On high power ZTR's like bad boys and Dixie choppers I've read you can run doubles and even triple mulchers. Haven't tried it yet myself ...

There won't be any grass barely coming out... it'll be like confetti.

images
 
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