Making custom shaped epoxy bin?

[Tim Good]

I have a slot under my sink but its hard to get a bin which fits. And the ones that do are often too small as they don't maximise the odd space beneath the sink.

I wanted to fabricate my own. If I shaped it from strong cardboard, do you think I could then layer up a thin coat of epoxy and mat around it to make a perfect bin?

 

[chris-s]

I’ve made numerous glassed parts by carving it from foam, undersized, wrapping in parcel tape and then layering glass on top and digging out the foam afterwards. Works great. I’ve made loads of bits and most recently a replacement anchor locker lid.

You might find card to flexible.

Chris

 

[V1701]

Pretty much anything that you gan get to hold the shape you want would do I'd have thought, it might look a bit weird & misshapen but that doesn't matter. I've been looking at polycarbonate roofing sheet as something to shape & glass over to form part of a hard sprayhood, I think that would do but they only sell it in fairly large pieces...

 

[thinwater]

Thin plywood is probably the best bet, about 4-5 mm. If you bond the corners using good fillets, round the corners and sand carefully, the glass is not needed. Hold it in place with brads will curing. Just paint with a good topcoat paint, sanding between coats. It will look like fiberglass. As for the glass, the most you will possibly need is 1 layer of finish cloth.

This trash can was made that way. No fiberglass. Same problem, I couldn't find anything the right size.

 

[lw395]

I made something a bit similar from grp panels cut out of a scrapped dinghy.
I was assuming the OP wanted it glossy inside for ease of cleaning?

 

[rogerthebodger]

I have a slot under my sink but its hard to get a bin which fits. And the ones that do are often too small as they don't maximise the odd space beneath the sink.

I wanted to fabricate my own. If I shaped it from strong cardboard, do you think I could then layer up a thin coat of epoxy and mat around it to make a perfect bin?

I have change to using HDPE sheet to make small items like trash bins.

I made an engine drip tray from HDPE sheet and of cause there are companies in the UK who fabricate water and fuel tanks from HDPE.

There is a glue now available that will glue HDPE together.

 

[LadyInBed]

If you wanted it glossy outside, I would make the initial shape out of stiff cardboard then build a plywood mold around it. Then you can remove the cardboard and smooth the corner profiles on the ply and coat the inside with a releasing agent.

 

[DownWest]

Method I used in the past was to lay up slightly oversized panels on melamine chipboard, then cut to size and fillet the joins. You get one smooth face that way.

 

[Neeves]

I made a custom box from glass and resin. I simply laid up a flat sheet, laid up on polythene from which it released cleanly,, and when it was touch 'set' I simply bent it to shape and laid it to set off hard round a cardboard former I had pre made. This gave me three sides. I then filled the fourth side and end with more sheet once everything was hard. There was a bit of trimming required - angle grinder with a tile cutter blade (a diamond tipped metal blade).

The glass is smooth on one side only - so if you want a smooth interior you need to bend the 'correct' way round.

The trick is catching the resin/glass when it is touch dry or touch set but still bendable.

I used a long strip of aluminium to give me a clean straight bend.


My method might not maximise strength - but for something non-loadbearing - it does not matter - and you could always reinforce should you need more strength.

Jonathan

 

[thinwater]

I made a custom box from glass and resin. I simply laid up a flat sheet, laid up on polythene from which it released cleanly,, and when it was touch 'set' I simply bent it to shape and laid it to set off hard round a cardboard former I had pre made. This gave me three sides. I then filled the fourth side and end with more sheet once everything was hard. There was a bit of trimming required - angle grinder with a tile cutter blade (a diamond tipped metal blade).

The glass is smooth on one side only - so if you want a smooth interior you need to bend the 'correct' way round.

The trick is catching the resin/glass when it is touch dry or touch set but still bendable.

I used a long strip of aluminium to give me a clean straight bend.


My method might not maximise strength - but for something non-loadbearing - it does not matter - and you could always reinforce should you need more strength.

Jonathan

Interesting. I've used that method to make sheets with a "bump" to allow for some minor equipment bulge. It saves making up a form in many cases. Just lay it up flat, wait, and then cover the item with a release fabric and drape it over. Generally it comes out pretty smooth, if you get the consistency right.

But for the OP's question, I would just knock up a plywood box in 5mm ply with brads, filet the joints, and then sand and finish. It will be light, stiff, and slick if you finish it right. Smooth inside and out. But it is all in the detail work.