[cbale2000]

Originally Posted by Bryce2471

I'm not able to picture how this construction method would be used here, but maybe I'm missing something.

So, for example, if you were using a foam center material, the process would look something like this:

1. Cut/sand foam to desired shape (for this example, a simple square box)
2. Find a clean flat surface (the cleaner and flatter the better), this will be the vacuum table
3. Lay down a layer of disposable absorbent material on the table (there are lots of options for this, you can even use common paper towels if you're working on the cheap)
4. Lay foam part flat on the table (on top of the aforementioned absorbent material)
5. Lay carbon fiber cloth on top of foam part, preferably cut so that it hangs just over half way down the sides of the part
6. Lay down a layer of "breather cloth" (basically a non-stick cloth material to prevent the absorbent material from sticking to the part and wicks away excess epoxy)
7. Add more absorbent material (paper towels) to the top of the part
8. Cover with plastic
9. Insert vacuum hose under plastic
10. Seal plastic completely to table using sticky tack (or similar), ensure the area around the hose is also sealed
11. Turn on air pump, run overnight
12. In the morning, remove part from bag, peel off breather cloth and absorbent material
13. Flip the part over and repeat steps 3-12 again
14. ???
15. Profit!

You can also use a space heater and half of a cardboard box to speed up the epoxy setting process if you want (don't leave it unattended though, for obvious reasons).

In the case of your design, you could use this method to basically make the whole thing with 5 pieces (or as one big piece if you were feeling really ambitious) and you wouldn't have to make the frame walls so wide (leaving more space for electronics and such).

And now for some related old pictures...

1, 2, 3, 4

Edit:

After re-reading your previous comment a few times, I'm thinking you might have been referring to how the construction method would be used in this situation, and not so much how it works (correct me if I'm wrong)... >_>
Answering that question might require some CAD work to explain unfortunately.