Final Part (Left), First (Right)

This is before trimming and gel coating, so it looks a little rough.

Final Part (Left), First (Right)

First Attempt

We initially tried to use 3 aluminum strips for a stronger part, but we encountered problems with voids in the part and uneven curing.

FEA With 55lbs of Force

FEA With 100lbs of Force

CATIA Model of Tool

Diagram of Foam Tool

Before Shaping

Diagram Showing How Tool Was Shaped

Gel Coated Foam Tool For Layup

After Some Use

Vacuum Molding

This isn't the bike mount, but it was made using the same process.