[ATM] ? Carbon Fiber Secondary Assembly

["Rod Shea" <RodShea@comcast.net>]

Can anyone point me to info about making a CF secondary assembly aka top cage?  I've been websurfing about this, and I've found a bewildering amount of materials and tools, but much less specifics, or information about how to think of this type of construction, like how to design with its strengths in mind.  I'm looking for reference books or websites about using the stuff, and more specific info like how may layers of what type(s) of fabric to use in what parts of the assembly.

I'm thinking of a ring shaped foam core with a NEWT determined ID, as high as the secondary and spider assembly together, solid where the focuser mounts  (? inset prefab composite panel), solid opposite that to allow for velcro'd on baffling, and solid where the spider vanes attach, but otherwise fairly open, to decrease wind loading.  Has anyone done something like this?

How have people dealt with reinforcing mounting points, like where the focuser, spider and truss tubes attach?  Is there a cheap way to make a hotwire cutter, or can you use a template and a RoboSander in a drillpress to cut the foam precisely?

Lastly, gee, how much weight can I really expect to save?  Is this a steep learning curve, and expensive materials, but not much actual benefit over aluminum and/or ApplePly plus Kydex or similar sheeting?

Thanks,

Rod

 
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