In order to provide a product that both Sir Hauls-A-Lot and our customers can be proud of, the most critical parts of the design are produced by our skilled technicians. Three parts that are integral to the design of the Pivotbarrow: the handles, the bucket support, and the caster support. A description of the manufacturing processes of these parts is outlined below.

The Handles
The handles are produced in a multistep process. It started off as a two-part polyurethane expanding foam that is poured into a pultruded glass fiber mold. The mold is sealed with duct tape to prevent the foam from seeping through the clamps and held in place by clamps. After the foam sets, the top of the handle is bored out to allow a PVC handle to be inserted; the PVC is held in place by a five-minute epoxy. Following this, the handle is enveloped by a glass fiber braid and placed onto a filament winder. West System 105/206 Epoxy resin is wet laid up on the handle with a brush, and excess resin is squeegeed off. A total of 3 glass layers are used, with a final layer of carbon fiber sleeving is used. A final layer of epoxy is used to guarantee a pristine surface finish, and afterwards the handle is machined to the correct dimensions, and final touches are completed.

The Bucket Support
The bucket support is constructed in a single session. The bucket support is molded directly onto the purchased plastic bucket to ensure an exact fit is achieved. Before this molding process can be started, the bottom of the bucket is covered in a wax coat that is buffed smooth. After waxing the bucket was sprayed with a healthy coat of Stoner Dry Film Mold Release, it was then left to dry. After this, the wet layup could begin. Due to the size of the part, the standard West System 105/206 Epoxy was not applicable; a longer gel point was necessary in its place, a CTD-521 Part A/B system was used. The CTD-521 system has a multi-hour working time, more than sufficient for our purposes. Eight glass fiber layers were laid up, with alternating layers having been cut from a different template; the alternating layers guaranteed complete coverage and structural stability of the part. After the glass layers, two alternating carbon fiber layers were introduced as the exterior layer of the bucket holder. The bucket was then placed inside a large vacuum bag; and after the vacuum was drawn placed inside the oven for 24 hours to reduce the length of the cure. After curing in the oven, the bucket was demolded and trimmed to size, ready for final touches.

The Caster Support
The caster support is produced in two nearly identical steps followed by a minor bonding step at the end. A solid polyurethane mold was cut to shape, and its edges filleted by a router. The entire mold is covered in a wax coat that is buffed smooth. After the waxing, the mold is rotated to its proper placement and was sprayed with a two coats of Stoner Dry Film Mold Release. After the release was dry, the wet layup commenced. At the first station, West System 105/206 Epoxy resin was used to wet-out a layer of carbon fiber, and excess was squeezed off; this wet-out ply was transferred to the second station, where it was placed carefully onto the mold. A total of 5 carbon layers were used in this process. The mold was then placed inside a vacuum bag and left to cure for 24 hours. This process was repeated, with the simple alteration of laying up on the opposite side of the mold, to make a mirror part. After halves are constructed, they are lined up and joined together using a generic five-minute epoxy. The joined part was then cut to shape and sanded. It was then ready for any final touches before assembly.