Dolphin shell repair

camerone · 27th February 2007, 17:24

Quote: (Originally Posted by tamorgen)

Probably a good idea. It does seem to be holding, just don't know what kind of stress it will hold up to.

Most special purpose plastic "glues" have some kind of solvent in them to actually chemically bond to the shell. MEK or acetone are fairly common as main ingredients. I usually buy mine at TAP Plastics because they're close to my house, but there's similar stores everywhere.

The fundamental problem with the Dolphin casing is that it's just flimsy, and you've got to carry a bailout somewhere. The harness isn't set up for slinging a bottle (plus, that makes wing inflation difficult), unless you add another d-ring to the back hip. That leaves the side of the case as your mounting point, but it's too thin to support a 19 cf or 30 cf bottle (which is what you need from ~100 feet).

I've got and old Dolphin sitting around that I've been tempted to convert to ccr, just for kicks, but the shell weaknesses are causing me grief, even when I put metal or plastic backing plates inside the case.

***sadave*** · 27th February 2007, 19:44

Quote: (Originally Posted by tamorgen)

Can anyone recommend a good epoxy or adhesive to repair a crack in the dolphin shell?

Yeah. Aluminium...

http://www.rebreatherworld.com/photo...oto/581/si/jdz
http://www.rebreatherworld.com/photo...oto/584/si/jdz
http://www.rebreatherworld.com/photo...oto/583/si/jdz

PM JDZ throught the forums here, I know there are quite a few ali dolphin shells out there on Rebreather World that he's made.

**Freef** · 28th February 2007, 14:54

I've not broken the shell yet, and I dive with a 3L 232 bar steel tank in the 'sock' on the right side of the shell.

For diving with bailout/deco stages I normally use a 7L 232 bar steel which is clipped to the harness, not the shell. I had to add a couple of D rings for that but it works well.

http://www.rebreatherworld.com/semi-...html#post38164

4ster · 28th February 2007, 15:34

So far I have not broken my shell either. I have an older Dolphin that came with the straps for mounting the bail out bottle, instead of the sock. The straps didn't do the job so I have fixed a locally manufactured pony mount to the shell. I had to drill 4 holes through the shell, and then I spread the stress around the holes with large nylon washers on the inside. So far, no cracks.

I also made a "spreader" for the lifting handle on the top of the shell. I was told by the local dealer that is the most likely place to crack, especially if it is used to lift the fully assembled Dolphin. The spreader is a 3/16in piece of UHMW polyethelene that has slots cut in it that match the slots in the shell. The straps from the handle go through the shell and the spreader so that the load is distributed over a larger area of the shell. I still try not to use the strap to lift the fully assembled Dolphin. I posted some pictures here:
http://www.rebreatherworld.com/semi-...forcement.html

I must admit that I am tempted by the aluminum shell above or maybe one of the stainless ones available.

tamorgen · 28th February 2007, 16:05

I don't know about the aluminum, but if I ever convert to mCCR, I plan to buy the stainless from Martin. Until then, I hope not to put too much stress on the unit. Hopefully it will hold, although I may try your reinforcement method.

**Freef** · 3rd March 2007, 07:37

Do any of the stainless or ally shells allow use of a 10L? The ones I've seen seem to enclose the bottle more than the standard Drager one.

27th February 2007, 17:24	#11 (permalink)
camerone New Member Current Rebreather/s: Evolution Dolphin Other Rebreather/s: Dolphin Join Date: Oct 2005 Location: Seattle, WA Posts: 72	Re: Dolphin shell repair Quote: (Originally Posted by tamorgen) Probably a good idea. It does seem to be holding, just don't know what kind of stress it will hold up to. Most special purpose plastic "glues" have some kind of solvent in them to actually chemically bond to the shell. MEK or acetone are fairly common as main ingredients. I usually buy mine at TAP Plastics because they're close to my house, but there's similar stores everywhere. The fundamental problem with the Dolphin casing is that it's just flimsy, and you've got to carry a bailout somewhere. The harness isn't set up for slinging a bottle (plus, that makes wing inflation difficult), unless you add another d-ring to the back hip. That leaves the side of the case as your mounting point, but it's too thin to support a 19 cf or 30 cf bottle (which is what you need from ~100 feet). I've got and old Dolphin sitting around that I've been tempted to convert to ccr, just for kicks, but the shell weaknesses are causing me grief, even when I put metal or plastic backing plates inside the case.
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27th February 2007, 19:44	#12 (permalink)
*sadave* Couldn't be bothered... Current Rebreather/s: Sport Kiss Other Rebreather/s: Not Bought Yet Classic Kiss Join Date: Jun 2005 Location: Brisbane, Queensland Posts: 1,052	Re: Dolphin shell repair Quote: (Originally Posted by tamorgen) Can anyone recommend a good epoxy or adhesive to repair a crack in the dolphin shell? Yeah. Aluminium... http://www.rebreatherworld.com/photo...oto/581/si/jdz http://www.rebreatherworld.com/photo...oto/584/si/jdz http://www.rebreatherworld.com/photo...oto/583/si/jdz PM JDZ throught the forums here, I know there are quite a few ali dolphin shells out there on Rebreather World that he's made. __________________ Wave!
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28th February 2007, 14:54	#13 (permalink)
Freef Custom Title Disallowed! Current Rebreather/s: Dolphin Other Rebreather/s: Dolphin Join Date: Jan 2006 Location: Land of the Freef, UK. Posts: 1,356	Re: Dolphin shell repair/slinging tanks. I've not broken the shell yet, and I dive with a 3L 232 bar steel tank in the 'sock' on the right side of the shell. For diving with bailout/deco stages I normally use a 7L 232 bar steel which is clipped to the harness, not the shell. I had to add a couple of D rings for that but it works well. http://www.rebreatherworld.com/semi-...html#post38164 __________________ David. Currently owner of two differently sized ankles. Last edited by Freef : 28th February 2007 at 14:59.
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28th February 2007, 15:34	#14 (permalink)
4ster Steve Sprague Current Rebreather/s: rEvo Other Rebreather/s: rEvo Join Date: Mar 2006 Location: Arlington, Washington Posts: 295	Re: Dolphin shell repair So far I have not broken my shell either. I have an older Dolphin that came with the straps for mounting the bail out bottle, instead of the sock. The straps didn't do the job so I have fixed a locally manufactured pony mount to the shell. I had to drill 4 holes through the shell, and then I spread the stress around the holes with large nylon washers on the inside. So far, no cracks. I also made a "spreader" for the lifting handle on the top of the shell. I was told by the local dealer that is the most likely place to crack, especially if it is used to lift the fully assembled Dolphin. The spreader is a 3/16in piece of UHMW polyethelene that has slots cut in it that match the slots in the shell. The straps from the handle go through the shell and the spreader so that the load is distributed over a larger area of the shell. I still try not to use the strap to lift the fully assembled Dolphin. I posted some pictures here: http://www.rebreatherworld.com/semi-...forcement.html I must admit that I am tempted by the aluminum shell above or maybe one of the stainless ones available. __________________ Steve "My problem is that I have trouble reconciling my gross habits with my net income." Errol Flynn
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28th February 2007, 16:05	#15 (permalink)
tamorgen Gadget guru extrordinaire Current Rebreather/s: Dolphin Other Rebreather/s: Dolphin Join Date: Apr 2006 Location: Columbia, MD Posts: 183	Re: Dolphin shell repair I don't know about the aluminum, but if I ever convert to mCCR, I plan to buy the stainless from Martin. Until then, I hope not to put too much stress on the unit. Hopefully it will hold, although I may try your reinforcement method.
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3rd March 2007, 07:37	#16 (permalink)
Freef Custom Title Disallowed! Current Rebreather/s: Dolphin Other Rebreather/s: Dolphin Join Date: Jan 2006 Location: Land of the Freef, UK. Posts: 1,356	Dolphin shells-bottles. Do any of the stainless or ally shells allow use of a 10L? The ones I've seen seem to enclose the bottle more than the standard Drager one. __________________ David. Currently owner of two differently sized ankles.
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