Laminating shell

[virreslirre]

Hello!

I've been seeing a lot of really fine examples of different shell-veneers put to use as scales.
I have, after a long search, found a supplier of abalone veneer in germany. I know theres masecraft but they have a rather high minimum amount for international orders so i disqualified them..

So, i have a few options here on how to do this and im hoping one of you experienced gentlemen could guide me towards the best choice.
The way i see it, i need to back the abalone with something dark or colored(spelling?) to lure out the colors from the abalone.

The veneer is about 0,5 mm thick and possibly brittle. its is a thin plastic film with embedded shell.

Option one -
Black acrylic backing/liner - shell laminate - clear acrylic front. All laminated with glue(for acrylics). Then shaping and so forth..

Option two -
Making some paper micarta with the last layer consisting of the shell laminate. Then rough-shaping and then som more epoxy-resin poured over to get a clear top-layer.
-I'm a bit discouraged by this method because of prior atempts with epoxy resin has made it clear to me that the mixing proportions have to be dead-on for it to cure correctly. The veneer is quite expensive and i dont want to fail.. I have veneer for about 3 atempts..

Option three -
Same as above but insted of pouring the resin after the backing and shell i use clear acrylic on top. A big hunk of paper-shell-acrylic-micarta so to speak..

What do you guys think i should do, any of the above, none of the above and something entierly different?

Thank you for your help!

Regards / Victor

 

[AllenG]

Full disclosure, haven't made my own scales--yet.

Mudhole.com <--fishing rod builders' supply house. They have abalone in small quantities.
I make bamboo fishing rods and have used abalone onlay several times.

It cracks very easily when applying it to a curved surface. When it arrives it will have an adhesive surface on one side. Soak it in quite hot water until the backing can be peeled off. It is sticky as all get out and you will only have one shot at it. Cut it to size first; make a paper template and use that as a guide. You can cut it with a razor or good scissors. Place it where you want and use a heat gun and a burnishing tool (the burnishing tool I use is one of those paper smudge sticks that are used in drawing) to smooth it in exactly where you want it.
There is a good how to video on the mudhole site showing its application They don't use a heat gun. I highly recommend that you do if you want it to go around a curve--hot water is not enough to make it pliable. I aslo recommend buying two strips and practice with the first.
After you have it on, coat it with an epoxy finish to protect it and give it depth. Unless you have a rotating dryer I would recommend a 5 min epoxy. Most of the rod building epoxies take hours to dry and will run all over the place is you don't keep the rod/razor/whatever moving (like how one keeps honey on the end of a wooden honey dipper).

Hope that is of some help.

PS. If you want to try snake skin, it's much easier to use (coat it in epoxy too).

[edit]
I didn't read your post throughly, I see that you already have your abalone and know about coating it in epoxy. Still, the above is how I put it on rods.

 

[cb91710]

Be very very careful when working with abalone and mother of pearl, as well as other natural shell materials.
Their dust has similar properties to asbestos. Work with them ONLY wet, and with full respiratory protection, and keep the waste materials wet until they are completely cleaned up and wrapped in plastic and sealed for disposal.

The material is safe to handle, but the dust can cause problems if inhaled.

 

[prsman23]

Ok. I've got to know about snake skin...
Where can you find it? I was going to make some micarta scales. Could it be used as the last layer and still cut an sanded into shape

 

[AllenG]

Ok. I've got to know about snake skin...
Where can you find it? I was going to make some micarta scales. Could it be used as the last layer and still cut an sanded into shape

Click on that Mudhole link in my above post. You'll find it there; it is sold by the inch. I don't think it would take sanding well. It's really soft leather (until you coat it with epoxy that is).

 

[virreslirre]

Thank you for all the input!
I really didnt know about the heating-procedure but i guess im going to do the homemade micarta-shell thing and the pour resin over. That way i wont be forced to sand on the shell-veneer at all, just shaping. Special thank you for the heads up on the toxic dust! I somehow missed that part. B&B - prolonging life

 

[virreslirre]

And of course, there will be pictures, probably mid next week.