- make a mold shape with an angled step. The step height should be equal to the 1 washer thickness + 1/2 the sheave thickness. (the sheave will have a s.s. washer on the inside between the two halves.) You can see the angled step shape with the shadow on it.
- cover the mold with mylar packing tape - best mold release ever
I'm not going to spell out the laminate schedule I used. If you've used carbon fiber before you will know how it's a bit harder to wet out for an amateur and I don't want to give everybody the impression that they will make a suitable block the first time using carbon. Composite properties depend very much on the skill of the laminator. If you are a so-so laminator the strength of the part might be as low as 1/3 the strength of a good laminator. For such a safety related part, I don't feel like being responsible for the design for others to copy.
- wet out the fabric with epoxy resin, cover with clear plastic and squeegee hard.
- cut part into 2 halves, round the corners
- assemble and test
How it looks in use
On a budget and can't afford a marine snatch block? Check out a rock climbing rescue pulley. You'll need a carbiner but quite cheap and strong.